Process Engineer (Starship)

PROCESS ENGINEER (STARSHIP)

As a Process Engineer with a focus on Starship build reliability, you will be part of a widely interdisciplinary team developing global manufacturing procedures, maximizing quality through efficient production. You will employ “reliability by any means necessary”, stretching your expertise in fabrication methods, work instructions, tooling design, inspection procedures, data gathering/visualization, and broad collaboration. You will build new processes from the ground up, and routinely grade/improve execution of existing processes, driving continuous production improvement and ultimately be responsible for build-induced vehicle risk.

RESPONSIBILITIES:

• Develop manufacturing, integration, assembly, welding, NDE, cleanliness, and checkouts processes from the ground up, then enforce consistency across different work centers.
• Design and implement tooling for work access, mechanical/avionics/propulsion testing, build fixturing, lifting & rigging, and fluids.
• Define and document inspection requirements and procedures.
• Create training for production and inspection processes.
• Author planning, test plans, and training to execute processes and collect data, ensuring efficient and stable quality at increasing production volumes.
• Contain non-conforming hardware in collaboration with quality, production, and design groups to ensure systemic issues are corrected, and risk is managed for the fleet.
• Work closely with design teams to improve DFM and requirement fulfillment. Aggressively modify requirements and manufacturing process where design intent and production rate are incompatible.
• Conduct build quality reviews to identify repeat and high impact issues. Drive corrective action within and outside of your work center.

BASIC QUALIFICATIONS:

• Bachelor's degree in mechanical engineering, aerospace engineering, materials engineering, manufacturing engineering, chemical engineering, electrical engineering, or engineering physics.
• 1+ years in manufacturing, quality, and/or design engineering role (student project team or internship experience qualifies).

PREFERRED SKILLS AND EXPERIENCE:

• Experience with the build, assembly, or integration of structures, avionics, valves, fluid system components, actuators, thermal protection systems, or other aerospace components.
• Mechanical tooling or component design and design for manufacturability.
• Proficiency with 3D CAD Software such as NX, SolidWorks, or CATIA.
• Knowledge of mig, tig, laser, stud, spot, or robot welding techniques, as well as visual, penetrant, x-ray, EMAT, or other NDT processes.
• Involvement in a collegiate or hobby design project (Formula SAE, rocketry, etc).
• Proficiency with SQL and Power BI or other database/query/data visualization suite.
• You thrive in a hands-on environment and are hungry to step out of the office, onto the shop floor.
• Knowledge of metallic manufacturing techniques, processes, and equipment related to machining, bending, forming, casting, additive manufacturing, fastening, drilling, and/or bonding.
• Strong interpersonal skills and ability to collaborate with partners/customers from a diverse set of engineering disciplines.

ADDITIONAL REQUIREMENTS:

• Ability to work extended hours, weekends, and offsite as needed.