BUILD SPECIALIST, BARREL PRODUCTION (STARSHIP)
The Build Specialist for Barrels and Domes Primary Structures focused on Root Cause, Escalations & Line Efficiency ensures quality, reliability, and efficient production of Starship’s core propellant tank structures. Through root-cause analysis, escalations ownership, and line optimization, the role enables the production rates and structural integrity needed for Starship’s high flight cadence.
RESPONSIBILITIES:
- Lead relentless, data-driven root cause analysis (5 Whys, fishbone, Pareto, etc.) on complex equipment failures, quality defects, process variability, and unplanned downtime; implement permanent countermeasures, poka-yoke solutions, and preventive/predictive strategies to eliminate repeat problems
- Own engineering escalations end-to-end: triage issues, coordinate with design/manufacturing/build reliability engineers, drive rapid resolution, verify fixes at the gemba, and document thoroughly for full traceability and compliance
- Drive day-to-day waste reduction and line efficiency on flexible barrel lines—optimize workflow, part flow, mixed-product sequencing, workstation layout, and material presentation to cut non-value-added time and improve throughput
- Troubleshoot complex equipment and tooling issues, support repairs, and manage model/tooling changes to minimize disruption
- Conduct quality inspections, enforce process standards, escalate non-conformances immediately, and mentor technicians on best practices and standard work
- Drive continuous improvement and 5S: update work instructions, standardize best practices to close skill gaps and accelerate knowledge transfer, and implement workstation/process optimizations
- Support assembly process updates, new equipment integration, and seamless cross-shift/cross-department coordination
- Partner with engineering to improve utilization efficiency—provide clear feedback, data, and recommendations that reduce rework loops and strengthen the production-engineering partnership
- Verify safety, compliance, and process integrity on the floor; ensure every fix is robust and sustainable
BASIC QUALIFICATIONS:
- High school diploma or equivalency certificate and 2+ years of professional experience in a hands-on manufacturing environment; OR Bachelor's degree in an engineering, math, or science discipline
PREFERRED SKILLS AND EXPERIENCE:
- Associate or bachelor's degree in an engineering, math, or science discipline
- 2+ years in a manufacturing, process planning, or continuous improvement role with strong root-cause ownership
- 2+ years of professional experience in an aerospace, aviation, automotive, and/or manufacturing environment
- Experience in automated laser welding / laser cutting
- Proven experience leading structured problem-solving (5 Whys, A3, 8D, etc.) and implementing permanent countermeasures that prevent recurrence
- Hands-on experience with Lean tools (5S, waste elimination, value-stream thinking, Kanban, OEE, PFMEA, poka-yoke)
- Strong data analysis skills (Excel, VBA, SQL, or similar) for downtime, quality, and efficiency metrics
- Experience mentoring technicians, enforcing standards, and driving knowledge transfer
- Experience with equipment troubleshooting, tooling changes, workstation optimization, and flexible/mixed-model lines
- Excellent written and verbal communication skills; ability to escalate clearly and partner effectively with engineering and leadership
- Experience taking processes from development through rate production with focus on design for manufacturability and assembly
ADDITIONAL REQUIREMENTS:
- Must be able to work all shifts, overtime, and weekends as needed
- Ability to stand for extended periods (8+ hours minimum)
- Must be able to lift up to 25 lbs unassisted (and up to 50 lbs for short durations)
- Must be able to travel up to 5%
- Ability to work at elevated heights (up to 200 feet) and in confined spaces
- Able to work outdoors (heat, cold, rain) and in environments with fumes, odors, and noise
- Physical demands (approximate daily):
- Stand/Walk: up to 10 hours
- Sit: up to 3 hours
- Push/Pull: up to 75 lbs (unassisted) 1–2 hours
- Overhead reach / Upper body twist / Kneel/Crouch: up to 6 hours
- Climb (ladder/stairs): up to 3 hours
- Lift/Carry: up to 50 lbs (unassisted) 1–2 hours
- Work in temperatures over 80°F for short periods (≤30 min)
