Director, Process Engineering

Department: Production: Process Engineering & NPI

Location: Dallas, TX

Employment Type: FullTime

Director, Process Engineering

Location: Dallas Fort Worth Metro Area / In Person

Employment Type: Full-Time

About Us

We are a stealth defense technology startup operating at the intersection of advanced hardware, modern manufacturing, and next-generation AI-enabled manufacturing software. Our mission is to design, build, and deliver real systems that address urgent strategic and industrial capability needs today.

The company is fully funded and has confirmed customer demand with orders exceeding projected manufacturing capacity through 2028.

Our team combines deep technical expertise across multiple disciplines with the operational rigor required to design, manufacture, deploy, and support systems in demanding real-world environments.

Our culture values execution, builders, doers, and ownership. We move quickly, solve hard problems, and take pride in turning ideas into working systems that deliver meaningful results for our customers and mission partners. If you enjoy building real systems and solving hard problems, we would like to learn more about you.

About the Team

Our teams span engineering, manufacturing, supply chain, operations, and software. Together, they design, build, and deploy complex systems that must work reliably in demanding real-world environments.

The organization operates with a strong bias toward execution. Engineers work closely with production teams, software interacts directly with hardware and factory systems, and supply chain and logistics ensure that components move efficiently from suppliers to production to delivery.

About the Job

We are seeking a Process Engineering Director to lead the development, qualification, and optimization of robust manufacturing processes for defense-grade components. This hands-on leadership role is critical to delivering mission-critical systems that meet stringent defense standards in a fast-scaling production environment.

What You’ll Do

· Develop and qualify robust industrial processes for defense-grade steel forgings, ensuring first article compliance with defense standards

· Lead first article inspections (FAI) and process validations to deliver battle-ready products

· Perform CpK/PpK statistical analysis and utilize root cause tools (8D, 5-Why) to ensure process capability and stability

· Apply Statistical Process Control (SPC) and statistical tools (Minitab, Excel, R-Shiny) to maintain tight process control

· Leverage deep expertise in metal processing, including heat treating and chemical coatings, to meet demanding defense specifications

· Drive Lean and Six Sigma methodologies to optimize processes and eliminate inefficiencies

· Serve as the primary process engineering point of contact for customers and suppliers

· Lead and develop a team of 4 shift supervisors and multiple process technicians operating across four shifts

Required Qualifications

· Education: Bachelor’s degree in Process Engineering, Industrial Engineering, Metallurgy, Materials Science, or Chemical Engineering

· Experience: 7–10+ years in process engineering management, with a proven track record developing and qualifying processes for defense, aerospace, or complex manufacturing/assembly environments (First Article Inspection experience strongly preferred)

· Technical Skills: Strong proficiency in CpK/PPK analysis, Statistical Process Control (SPC), and RCCA tools (8D, 5-Why); hands-on experience with Minitab, Excel, and R-Shiny

· Leadership & Work Style: Hands-on leader and team builder who thrives in high-pressure, fast-paced environments

· Soft Skills: Excellent communication skills with the ability to coach, mentor, and proactively solve problems

· Physical Requirements: Ability to stand, walk, and lift up to 50 lbs in a gritty manufacturing shop environment with heat and noise

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

· Deep knowledge of defense standards (MIL-STD, ITAR)

· Expertise in metal processing, including heat treating and chemical coatings for ferrous, non-ferrous, and super alloys

· Experience with non-destructive testing (NDT) methods such as ultrasonic and dye penetrant for process validation

· Six Sigma Black Belt or ASQ Certified Manufacturing Engineer (CMfgE)

Benefits

· Medical, Dental, and Vision Coverage

· Paid Time Off (PTO)

· 401(k) Plan

· Relocation Assistance (depending on role eligibility)

The recruiter assigned to this role can share more information about the specific compensation and benefit details associated with this role during the hiring process.