Sr. Manufacturing Engineer - Lean Manufacturing & Continuous

Company Overview

ARA is a leading C5ISR company that designs, manufactures, tests and installs innovative technologies that provide the national security community with unparalleled situational awareness, threat detection, and communications capabilities.

Our disruptive, integrated solutions, assemblies and subsystems rise to the challenging demands of discerning, mission-critical customers.

We leverage our capabilities to meet and exceed the requirements of our customers and empower them to remain ahead of evolving threats and complexities in a dynamic security landscape.

Job Summary

The Sr. Manufacturing Engineer is responsible for leading and implementing Lean manufacturing, continuous improvement, and manufacturing process optimization initiatives within a high-reliability RF/electronics manufacturing environment supporting military and defense customers.

This position focuses on eliminating waste, improving production flow, reducing manufacturing lead times, increasing throughput, improving first-pass yield, and reducing operational costs through the application of Lean manufacturing principles, Six Sigma methodologies, and data-driven problem solving. Core responsibilities include implementing and sustaining 5S workplace organization, leading Value Stream Mapping (VSM) activities, developing standardized work, facilitating Kaizen events, and executing continuous improvement projects.

The successful candidate will demonstrate the ability to identify improvement opportunities, establish measurable performance baselines, lead cross-functional improvement projects, validate results, and implement controls to sustain long-term gains. Working closely with Production, Quality, Design Engineering, Supply Chain, and Operations leadership, this individual will translate Lean concepts into practical shop-floor improvements while maintaining product quality, process control, traceability, and compliance with applicable customer and industry requirements.

Essential Functions

Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

1. Lean Manufacturing & Continuous Improvement

• Lead and implement Lean manufacturing initiatives to eliminate waste, improve productivity, reduce manufacturing lead times, increase throughput, improve quality, and lower operational costs.
• Implement and sustain 5S workplace organization programs, including Sort, Set in Order, Shine, Standardize, and Sustain. Establish workplace standards, visual controls, audit schedules, area ownership, performance measures, and corrective actions to maintain improvements.
• Lead current-state and future-state Value Stream Mapping (VSM) activities to identify non-value-added activities, bottlenecks, excessive work-in-process, process delays, and opportunities to improve material and information flow. Translate findings into prioritized implementation plans with measurable improvement targets.
• Develop and execute Lean improvement roadmaps addressing process flow, work-in-process reduction, material presentation, point-of-use storage, standard work, visual management, and waste elimination.
• Facilitate Kaizen events and cross-functional improvement workshops that engage production personnel, challenge existing processes, and drive practical, sustainable improvements.
• Apply Lean tools, including standard work, visual management, mistake-proofing (Poka-Yoke), workplace organization, line balancing, and setup or changeover reduction, as appropriate to the manufacturing process.
• Maintain a continuous improvement pipeline by identifying opportunities, evaluating potential benefits, prioritizing projects, and tracking implementation progress.
• Conduct periodic audits and follow-up assessments to verify adherence to Lean standards, identify gaps, and implement corrective actions to prevent regression.

2. Continuous Improvement Project Leadership & Measurable Results

• Lead assigned Lean Six Sigma and continuous improvement projects from problem definition through implementation, validation, and sustainment. Develop project charters, define scope and objectives, identify stakeholders, establish schedules, assign responsibilities, and communicate progress and results.
• Establish baseline performance, define measurable improvement targets, and identify appropriate operational and financial metrics before implementing process changes.
• Track and analyze key performance indicators (KPIs), including cycle time, manufacturing lead time, work-in-process, first-pass yield, scrap, rework, throughput, labor efficiency, on-time delivery, and overall equipment effectiveness (OEE), where applicable.
• Verify and document project outcomes by comparing post-implementation performance against established baselines, validating operational and financial benefits, and communicating results and recommendations to stakeholders and leadership.
• Develop and implement sustainment plans incorporating standard work, process controls, visual performance measures, audit schedules, and assigned ownership to ensure improvements remain effective over time.
• Apply cost-benefit analysis and return-on-investment assessments, where appropriate, to prioritize improvement opportunities and support capital equipment or process improvement proposals.
• Coordinate with Production, Quality, Engineering, Supply Chain, and Operations leadership to resolve implementation barriers, manage competing priorities, establish accountability, and deliver projects within agreed scope and schedules.
• Take ownership of assigned improvement initiatives through completion, ensuring that implementation, results verification, documentation, and sustainment activities are completed.

3. Lean Six Sigma & Structured Problem Solving

• Apply DMAIC (Define, Measure, Analyze, Improve, Control), root cause analysis, 5 Whys, Fishbone diagrams, Pareto analysis, and other structured problem-solving methodologies to identify causes of manufacturing inefficiencies and recurring issues.
• Lead or support corrective and preventive actions to reduce recurring defects, scrap, rework, production delays, excessive handling, and other sources of manufacturing waste.
• Use data, statistical analysis, and critical thinking to evaluate process performance, validate root causes, assess potential solutions, and prevent recurrence of identified problems.
• Coach production personnel, technicians, and engineering colleagues in Lean principles, structured problem solving, and continuous improvement practices to strengthen problem-solving capability across the organization.

4. Manufacturing Process Optimization

• Analyze manufacturing processes to identify bottlenecks, improve workflow, optimize labor and equipment utilization, and reduce unnecessary movement, handling, waiting, and processing.
• Conduct time studies, work-content analysis, capacity assessments, line balancing, and cycle-time evaluations to establish production standards and identify opportunities to improve manufacturing performance.
• Develop, document, and maintain standard work, work instructions, standard operating procedures (SOPs), process flows, and visual work aids to promote consistent execution and repeatable results.
• Design and implement jigs, fixtures, tooling, equipment modifications, and manufacturing process improvements in collaboration with Design Engineering, Production, Quality, and suppliers.
• Evaluate opportunities for automation, error-proofing, improved material presentation, and simplified manufacturing methods to improve productivity, quality, and process reliability.
• Support Design for Manufacturability (DFM), New Product Introduction (NPI), manufacturing readiness, and process validation activities to ensure processes are capable, efficient, and suitable for production.
• Apply statistical analysis, statistical process control (SPC), and process-control techniques, as appropriate, to improve yield, reduce defects, and maintain stable, repeatable manufacturing performance.

5. Quality, Compliance & Defense Manufacturing

• Ensure manufacturing process improvements comply with applicable ISO standards, industry requirements, customer-specific requirements, and established quality management system procedures.
• Maintain accurate manufacturing documentation in collaboration with Quality and Design Engineering, including applicable process flows, PFMEAs, control plans, work instructions, and process validation records.
• Support process validation, first-article activities, and manufacturing readiness for new and revised products.
• Ensure Lean initiatives and process changes maintain product quality, traceability, configuration control, process integrity, and applicable defense manufacturing requirements.
• Evaluate proposed process changes for potential quality, compliance, and production risks before implementation and coordinate required reviews, approvals, and documentation updates.
• Comply with applicable requirements for handling controlled technical information and customer data.

6. Cross-Functional Collaboration & Technical Leadership

• Work directly with production personnel, technicians, supervisors, and engineering teams to identify improvement opportunities, understand operational challenges, and implement practical shop-floor solutions.
• Provide technical guidance and Lean manufacturing support to Manufacturing Engineer I personnel and production technicians, promoting consistent application of engineering practices and continuous improvement methods.
• Facilitate training in 5S, Value Stream Mapping, standard work, visual management, root cause analysis, and other applicable Lean tools to build organizational capability and employee engagement.
• Communicate project objectives, performance measures, implementation plans, risks, results, and recommendations clearly to stakeholders at appropriate organizational levels.
• Collaborate across Production, Quality, Engineering, Supply Chain, and Operations to align improvement activities with business priorities, customer expectations, and manufacturing requirements.
• Support capital equipment justifications, resource planning, and continuous improvement proposals by presenting data-driven recommendations, demonstrated operational needs, and expected financial or performance benefits.
• Promote a culture of ownership, accountability, collaboration, and customer focus by encouraging employee participation, sharing improvement results, and reinforcing adherence to quality and process standards.

Position Qualifications

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Competency Statements

• Adaptability - Adapts to change, open to new ideas and responsibilities
• Communication - Ability to communicate thoughts clearly, both oral and written in an honest, open and timely manner
• Job Knowledge - Understands facets of job, aware of duties and responsibilities, keeps job knowledge current
• Technical Skill - Possesses the knowledge and skills needed to perform a job or role effectively
• Dependability - Meets deadlines, works independently or in a team environment, is accountable, maintains focus, good attendance record
• Quality - Strives to eliminate errors, accurate work is a priority, seeks opportunities to improve products
• Ethics - Honest, accountable, maintains confidentiality
• Initiative / Take Ownership - Takes action, seeks new opportunities, strives to see projects to completion, meaning own your job and see it through
• Decision Making – Problem solve and critical thinking skills, be able to reach a decision, takes thoughtful approach when considering options, seeks input from others, makes difficult decisions
• Customer Focus - Understands and can meet the needs in a customer-centric (Internal and External) environment and build strong relationships. Promotes a positive image of the company and strives to solve issues raised by customers

Experience and Skills

Required Experience and Technical Skills

• 8+ years of experience in manufacturing engineering, industrial engineering, Lean manufacturing, continuous improvement, or related discipline.
• Demonstrated hands-on experience implementing Lean manufacturing tools, including 5S, standard work, visual management, waste reduction, and process-flow improvement.
• Experience implementing or sustaining 5S programs, including workplace organization standards, visual controls, audit systems, area ownership, and corrective actions to maintain improvements.
• Hands-on experience conducting Value Stream Mapping (VSM), including current-state analysis, future-state development, identification of bottlenecks and non-value-added activities, and implementation of improvement plans.
• Demonstrated ability to lead continuous improvement projects from initial problem definition through implementation, validation, and sustainment, including coordination with cross-functional stakeholders.
• Proven ability to quantify improvement results by establishing baseline performance, defining measurable targets, tracking KPIs, validating benefits, and implementing controls to prevent regression.
• Experience delivering measurable improvements in one or more manufacturing performance areas, such as cycle time, lead time, work-in-process, throughput, first-pass yield, scrap, rework, labor efficiency, or manufacturing cost.
• Experience using Lean Six Sigma methodologies, including DMAIC, root cause analysis, 5 Whys, Fishbone diagrams, Pareto analysis, and corrective action methods.
• Ability to conduct time studies, work-content analysis, capacity analysis, line balancing, and process-flow evaluations.
• Strong understanding of manufacturing processes, materials, tooling, equipment, and process controls in a high-mix, low-to-medium-volume manufacturing environment.
• Experience developing and maintaining work instructions, standard operating procedures, process flows, PFMEAs, control plans, and process validation documentation, as applicable.
• Proficiency with Microsoft Excel or equivalent analytical tools for data analysis, performance tracking, and project reporting.
• Familiarity with CAD tools such as SolidWorks, GD&T, ERP systems, MES platforms, and QMS systems such as Costpoint and TIPQA.
  Preferred Experience and Certifications
• Lean Six Sigma Black Belt certification strongly preferred, with demonstrated experience leading complex, cross-functional improvement projects.
• Lean Six Sigma Green Belt certification with demonstrated success delivering measurable improvement projects will also be considered.
• Experience facilitating Kaizen events, coaching employees in Lean tools, and promoting continuous improvement across production teams.
• Experience with statistical process control (SPC), process capability analysis, measurement systems, and other quantitative improvement methods.
• Experience supporting RF, microwave, electronics, C5ISR, aerospace, or defense manufacturing.
• Familiarity with applicable ISO quality management systems and customer-specific manufacturing requirements.

Education

• Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or a related engineering discipline.
• Additional coursework or professional training in Lean manufacturing, Six Sigma, statistical process control, industrial engineering, or operational excellence is preferred.