Staff Manufacturing Engineer
Confirmed on the employer's own hiring board on Nov 3, 2026. First seen by Alion on Sep 8, 2026. GTI Fabrication scores B on the Alion truth index.
Role Summary
The Staff Manufacturing Engineer serves as a technical expert on the Global Strategic Growth (GSG) team. In this role, you will evaluate, design, and validate the manufacturing frameworks required to execute complex capacity expansion projects-including greenfield and brownfield site builds, strategic joint ventures, partnerships, and targeted acquisitions.
Working upstream of traditional operations, you will translate high-level demand projections into fully defined manufacturing requirements across facilities, equipment, processes, labor, quality systems, and EHS compliance. Your technical due diligence assessments, CAPEX/OPEX models, and risk-mitigation frameworks will directly inform executive go/no-go decisions and set the baseline for plant readiness.
Key Responsibilities
- Design and lead manufacturing due diligence evaluations for prospective targets, partners, joint ventures, and new site locations.
- Establish site-visit agendas, evaluation criteria, and empirical evidence protocols to validate true production capacity and capability.
- Assess site capability across key processes, including heavy fabrication, structural welding, coating/finishing, mechanical and electrical integration, assembly, testing, and packaging.
- Translate product design, customer demand, and regulatory criteria into technical requirements for plant layout, tooling, equipment, labor, and quality systems.
- Rigorously validate stated plant capacity using TAKT time, cycle time, overall equipment effectiveness (OEE), uptime, shift models, changeover mechanics, yield, rework rates, and material flow analysis.
- Develop current-state and future-state value stream maps, conceptual line layouts, equipment specs, tooling requirements, and facility utility assumptions.
- Estimate CAPEX budgets, one-time launch expenditures, recurring operational cost impacts, and resource schedules required to close identified operational gaps.
- Quantify operational gaps against GTI standards, evaluating associated safety, quality, schedule, delivery, and business continuity risks.
- Maintain technical risk registers, decision logs, and close-gap action trackers; define formal technical conditions required prior to contract execution or investment approval.
- Support make/buy analyses, site selection, partner selection, and capital allocation with data-driven recommendations.
- Lead equipment technical reviews, supplier evaluations, installation, commissioning, process validation, and readiness tracking when projects advance to execution.
- Partner with Operations, Engineering, and NPI leadership to establish clear manufacturing handoff criteria and transition projects to sustaining ownership.
- Standardize diligence toolkits, templates, checklists, and manufacturing benchmarks; mentor junior engineering personnel on complex manufacturing challenges.
Technical Due Diligence & Site Assessments
Capacity Modeling & Constraint Analysis
Plant Planning, Layout & Capital Costing
Risk Management & Decision Support
Execution Handoff & Launch Readiness
Required Qualifications
Education & Experience: Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or a related technical discipline, paired with 8+ years of experience in manufacturing engineering, process design, and facility expansion within complex mechanical, electrical, or structural assembly environments.
Technical Due Diligence & M&A: Demonstrated experience conducting technical due diligence assessments, site evaluations, and gap analyses for target acquisitions, joint ventures, strategic supplier partnerships, or new site selection (greenfield/brownfield).
Advanced Capacity & Process Modeling: High proficiency in industrial engineering methodologies, including TAKT time, cycle time analysis, constraint/bottleneck identification, OEE, shift modeling, yield/rework analysis, and Value Stream Mapping.
Capital Costing & Line Design: Proven ability to create conceptual plant and line layouts, define equipment and tooling specifications, and build accurate CAPEX, launch cost, and utility/infrastructure estimates.
Commissioning & Launch Readiness: Practical experience leading equipment technical reviews, supplier evaluations, installation, commissioning, process validation, and formal operational handoffs.
Risk & Decision Governance: Experience establishing technical risk registers, decision logs, and conditional acceptance criteria to guide capital allocation and executive go/no-go decisions.
Preferred Qualifications
- Education: Master’s degree in Engineering, Systems Engineering, or Business Administration (MBA).
- Cross-Functional Leadership: Demonstrated ability to influence and align multi-disciplinary teams-including Executive Leadership, Real Estate, EHS, Quality, Finance, Legal, and Supply Chain-without direct reporting authority.
- Multi-Site Operations: Prior experience managing technical evaluations or launch readiness across geographically dispersed manufacturing facilities.
- Continuous Improvement Certification: Lean Six Sigma Black Belt or equivalent certification in continuous improvement methodologies.