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Salary: USD 140,000 - 180,000 / annual
Mach Industries, founded in 2023, is a rapidly growing defense technology company (~350 employees) focused on next-generation autonomous defense platforms. This is a hands-on technical leadership role with direct reports.
You will be Mach's expert on tooling design and design-for-manufacturability/automation (DFMA). Your core responsibilities span five areas:
**Tooling & DFMA Standards**: Write, publish, and maintain Mach's Tooling and Design-for-Automation guide covering design rules with test data, preferred materials and approaches, locating features, worked examples, and review checklists. Establish tooling standards for datum strategy, modular fixtures, clamping, and materials. Define design-for-automation rules for parts (gripping, locating, feeder compatibility, robot access). Set metrology and verification standards (laser tracker, CMM, vision). Define DFMA sign-off criteria at design gates. Track DFMA metrics per program (part count, assembly time, automation rate, tooling cost, lead time, first-pass yield). Keep standards current with production lessons and train design/manufacturing teams.
**Early Design Influence**: Review vehicle architecture and material choices at concept stage, focusing on datums and automated handling. Run DFMA studies at part, assembly, and system levels with data-backed feedback. Lead static and kinematic assembly studies (virtual builds) to validate robot reach, tool access, clearance, and install paths. Drive content reduction, simpler assembly, build-in-quality, and ergonomic access. Push for wider tolerances where performance allows and features suited to automation. Lead value engineering on released designs.
**Trade Studies & Make-vs-Buy**: Provide Vehicle Assembly teams with tooling cost, lead-time, capital, and rate data for automation trades (manual vs. semi-automated vs. fully automated). Build should-cost and rate models showing how design and automation choices affect cost, capital, schedule, and quality. Write RFQ requirements for tooling and automation equipment; help evaluate supplier quotes.
**R&D Leadership**: Set and run a tooling and automation R&D roadmap. Lead R&D on reconfigurable and low-cost fixturing, additive tooling, fixtureless and vision-guided assembly, robotic drilling and fastening. Plan and run designed experiments (DOE), build test articles and prototype cells, analyze results statistically, and publish findings. Capture inventions and work with Legal on patents. Design and deliver prototype tooling for development and validation builds; lead manufacturing trials on real hardware. Release proven processes to production with process specs, qualification criteria, process capability (Cp/Cpk), measurement capability (GR&R), and inspection methods.
**Tool Lifecycle & Supplier Support**: Own the lifecycle of critical tools from feasibility and simulation through design, build, supplier buyoff, delivery, and production handoff. Design and oversee build of critical fixtures, jigs, end effectors, and assembly tooling. Run tool design reviews and buyoffs at tool shops. Bring tooling expertise to design and process FMEAs (DFMEAs and PFMEAs); maintain a library of known failure modes and proven controls. Lead root cause analysis on tooling-related escapes and repeat defects. Mentor engineers and help build Mach's DFMA function.
**Requirements**
- BS in Mechanical, Manufacturing, or Industrial Engineering, or equivalent experience
- 8+ years designing production tooling, fixtures, or end effectors for automated or high-rate assembly in aerospace, automotive, defense, or consumer electronics
- Expert in GD&T (ASME Y14.5), datum schemes, and tolerance stack-ups across parts and tooling, including dimensional variation analysis
- Experience integrating tooling with robots and automated cells, including equipment selection and ROI justification
- Track record of writing design standards, design guides, or process specs
- Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics, ROI
- Skilled in 3D CAD (NX, CATIA, SolidWorks, or similar)
- First-principles thinker with bias for action; challenges assumptions with data
- Comfortable on production floor and in lab, not just at desk
- Clear writer who can influence design decisions
**Preferred Qualifications**
- Journeyman Tool and Die Maker certification or equivalent toolmaker background
- MS in Mechanical or Manufacturing Engineering or related field
- Experience with both aerospace assembly tooling and automotive assembly automation
- Familiarity with PLCs, robot programming, and machine safety standards
- Large-scale metrology experience
- Formal DFMA methods (e.g., Boothroyd Dewhurst), should-cost modeling, value engineering with measured savings
- Assembly and robot simulation tools (e.g., Siemens Process Simulate, DELMIA)
- Experience leading DFMEAs and PFMEAs
- Patents, publications, or processes developed and put into production
- AS9100 or defense production environment experience
- Lean or Six Sigma certification
**Additional Requirements**
- Available to work extended hours and weekends as needed
- ITAR eligibility: Must be U.S. citizen, national, lawful permanent resident, Refugee, or Asylee, or eligible to obtain required authorizations from U.S. Department of State
