Sr. Manufacturing Process Flow & Control DFX Engineer

Application close date:

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!

Blue Origin's Emerging Systems business unit is building TeraWave, a satellite communications constellation powered by the most advanced optical communications architecture ever attempted: thousands of optically interconnected satellites delivering symmetrical data speeds of up to 6 Tbps anywhere on Earth, providing enterprise and hyperscale customers with resilient, scalable connectivity for critical operations where terrestrial infrastructure cannot reach.

As a Senior Manufacturing Process Flow & Control DFX Engineer, you will own the end-to-end manufacturing process flow and process control design integration for TeraWave production - bridging production line architecture, process control systems, and volume production readiness. As a foundational element of TeraWave operations, hardware must be produced through process flows architected not only for throughput but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, optimized, and scaled complex manufacturing process flows and control systems in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale.

Special Mentions:

• Relocation assistance is available for qualified candidates.
• Travel: Up to 50%.

What You'll Do

Manufacturing Line Architecture & Flow Design

• Design and own the end-to-end manufacturing process flow, defining how individual manufacturing cells are physically and logically connected to form a complete production line
• Develop and maintain Value Stream Maps (VSMs) and Process Flow Diagrams (PFDs) that represent the full material and information flow across the production system
• Establish manufacturing cell interfaces - defining inputs, outputs, handoff criteria, and interdependencies between cells
• Lead Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Testability (DFT) reviews to ensure products and processes are optimized for flow and control
• Identify and eliminate bottlenecks, waste, and flow disruptions using Lean manufacturing principles and systematic analysis

End-to-End Process Control

• Define and implement process control strategies at the line level, ensuring that critical process parameters (CPPs) and critical quality attributes (CQAs) are monitored and controlled across all cells
• Develop Control Plans and Process Control Documents (PCDs) that span the entire manufacturing line, not just individual operations
• Establish inter-cell control gates - defining hold/release criteria that must be satisfied before work-in-progress (WIP) moves between manufacturing cells
• Partner with Manufacturing Engineering, Quality, and Automation teams to implement Statistical Process Control (SPC) and real-time monitoring solutions at the line level
• Drive first-pass yield improvement and escape prevention through proactive process control strategies

Verification & Test Integration (End-to-End)

• Serve as the DFX technical authority for verification and test strategy across the full manufacturing line, ensuring every product characteristic is tested at the right point in the flow
• Define the test coverage matrix, mapping product requirements and process risks to specific test and inspection points throughout the production flow
• Partner with Test Engineering to design in-process verification stations, functional test sequences, and acceptance test procedures (ATPs) that are integrated into the line flow
• Ensure test data traceability - all test results, process data, and verification records are captured, linked to serialized hardware, and accessible for downstream decision-making
• Lead the development of Go/No-Go criteria and accept/reject disposition workflows at each verification gate within the line
• Drive DFT (Design for Testability) initiatives with product design teams to improve test access, observability, and controllability

Digital Thread & Data Architecture

• Own the manufacturing data architecture for the production line - defining what data is collected, where, how it flows, and how it is used for real-time control and traceability
• Partner with Manufacturing IT and Digital Engineering teams to implement Manufacturing Execution System (MES) workflows that enforce process sequencing, capture verification data, and flag non-conformances
• Ensure end-to-end serialization and traceability of hardware, materials, and process records from first operation to final acceptance
• Leverage manufacturing data to perform line health analytics, identifying systemic issues before they result in escapes or delivery impacts

DFX Leadership & Design Partnership

• Engage with product design teams early in the development lifecycle to influence design decisions through the lens of manufacturability, flow efficiency, and testability
• Lead formal DFX reviews (DFM, DFA, DFT, DFI, DFC) at key program milestones (PDR, CDR, PRR, MRR)
• Identify design features that create flow disruptions, rework loops, or untestable conditions, and drive design changes to resolution
• Champion the use of digital twins and virtual factory simulations to model and validate line flow prior to physical implementation

Continuous Improvement & Line Readiness

• Lead Production Readiness Reviews (PRRs) and Line Readiness Assessments (LRAs) to validate that the full manufacturing line - including all inter-cell connections and verification points - is ready for rate production
• Drive continuous improvement initiatives targeting line throughput, flow efficiency, first-pass yield, and test cycle time
• Develop and maintain line performance dashboards tracking key metrics: takt adherence, WIP levels, yield by cell, test pass rates, and escape metrics
• Support root cause analysis (RCA) and corrective action for systemic line-level issues

Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical field
• 10+ years of experience in manufacturing engineering, production systems, or process engineering in an aerospace, defense, automotive, or high-complexity manufacturing environment
• Demonstrated experience designing or improving end-to-end manufacturing flows with multiple interconnected process steps
• Working knowledge of process control methodologies - Control Plans, PFMEA, SPC, CPK analysis
• Experience defining or implementing verification and test strategies within a production environment
• Strong understanding of Lean Manufacturing principles - flow, pull, takt, waste elimination, value stream mapping
• Proven ability to work cross-functionally across engineering, quality, operations, and supply chain
• Strong analytical and problem-solving skills with a data-driven approach to decision-making

Preferred Qualifications

• Master's degree in Engineering or Manufacturing Systems
• Experience with propulsion systems, structures, avionics, or fluid systems manufacturing
• Hands-on experience with MES platforms (e.g., Solumina, SAP ME, Sight Machine, or similar)
• Familiarity with digital twin or simulation tools for manufacturing (e.g., Siemens Plant Simulation, Arena, or similar)
• Experience with automated test systems and functional test development for complex hardware
• Knowledge of AS9100, AS9102 (FAI), and NASA/DoD manufacturing standards
• Lean Six Sigma Green Belt or Black Belt certification
• Experience in a high-mix, low-volume manufacturing environment with serialized hardware traceability requirements
• Familiarity with Model-Based Definition (MBD) and Model-Based Enterprise (MBE) environments

What You'll Bring

• A systems thinker who sees the entire manufacturing line as an integrated system, not a series of isolated operations
• Deep passion for building discipline into manufacturing - ensuring that every control, verification, and handoff is purposeful and rigorous
• Comfort operating in ambiguous, fast-paced environments where you will help define the processes before they fully exist
• A collaborative spirit with the ability to influence without authority across engineering and operations teams
• An uncompromising commitment to safety and quality in everything you do

Base Pay Range for:

Other site ranges may differ

Culture Statement

Don’t meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.

Export Control Regulations

Applicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Background Check

• Required for all positions: Blue’s Standard Background Check
• Required for Certain Job Profiles: Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installation
• Required for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVWR) or combination of power unit and trailer that meets or exceeds 10,001 lbs. and/or transports placardable amounts of hazardous materials by ground in any vehicle on a public road while in commerce, may be subject to additional Federal Motor Carrier Safety Regulations including: Driver Qualification Files, Medical Certification (obtained before onboarding), Road Test, Hours of Service, Drug and Alcohol Testing, vehicle inspection requirements, CDL requirements (if applicable) and hazardous materials transportation/shipping training.
• Required for certain Job Profiles: Ability to obtain and maintain Merchant Mariner Credential, which includes pre-employment and random drug testing as well as DOT physical

Benefits

• Benefits include: Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with a company match of up to 5%, and an Education Support Program.
• Stock Options for all regular employees (working at least 20 hours/week)
• Paid Time Off: Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.
• Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.

Equal Employment Opportunity

Blue Origin is proud to be an Equal Opportunity/Affirmative Action Employer and is committed to attracting, retaining, and developing a highly qualified and dedicated work force. Blue Origin hires and promotes people on the basis of their qualifications, performance, and abilities. We support the establishment and maintenance of a workplace that fosters trust, equality, and teamwork. We provide all qualified applicants for employment and employees with equal opportunities for hire, promotion, and other terms and conditions of employment, regardless of their race, color, religion, sex, sexual orientation, gender identity, national origin/ethnicity, age, physical or mental disability, genetic factors, military/veteran status, or any other status or characteristic protected by federal, state, and/or local law. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws. For more information on “Know Your Rights,” please see here.

Affirmative Action and Disability Accommodation

Applicants wishing to receive information on Blue Origin’s Affirmative Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at [email protected]. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.