Senior Industrial Engineer

Summary:

The Senior Industrial Engineer will lead the development and optimization of manufacturing systems, production layouts, and operational workflows supporting both R&D and production of eVTOL aircraft. This role is responsible for designing scalable factory layouts, defining production stations, developing takt and cycle time strategies, and driving manufacturing efficiency as Pivotal transitions from prototype builds to commercial production.

You will partner closely with Manufacturing, Production, Supply Chain, Facilities, Design Engineering, Quality, and Program Management to establish world-class manufacturing operations capable of supporting rapid growth and production scaling. This includes ownership of production flow analysis, workstation design, line balancing, labor planning, material presentation strategies, and continuous improvement initiatives across the factory.

The ideal candidate has extensive experience in aerospace, automotive, or advanced manufacturing environments and thrives in fast-paced startup settings where ambiguity, rapid iteration, and hands-on problem solving are part of daily operations. If building production systems from the ground up, optimizing factory performance, and helping shape the future of aviation excites you, this is the role for you.

Responsibilities:

Manufacturing Layout & Factory Design

• Develop and optimize factory floor layouts to support efficient production flow, scalability, safety, and operational readiness.
• Create 3D plant layouts in Dassault Systems 3DEXPERIENCE (3DX).
• Design and implement manufacturing workstations, assembly cells, and material flow strategies for aircraft production and sub-assembly operations.
• Partner with Facilities, Manufacturing, and Production teams to support factory expansion, equipment placement, and infrastructure planning.
• Simulate manufacturing flow to identify bottlenecks and improve throughput.
• Support facility planning for prototype, low-rate initial production, and future rate production environments.
• Support manufacturing engineering by creating work instructions and standard processes across the manufacturing floor.

Production Planning & Industrial Engineering

• Conduct cycle time studies, takt time analysis, labor balancing, and capacity modeling to support production targets.
• Develop standardized work, labor models, staffing plans, and operational metrics for manufacturing processes.
• Establish manufacturing KPIs and dashboards to track efficiency, throughput, labor utilization, and operational performance.
• Lead line balancing and workstation optimization efforts to improve productivity and reduce waste.
• Analyze production data and recommend improvements to increase manufacturing efficiency and reduce operational risk.

Process Improvement & Lean Manufacturing

• Drive Lean Manufacturing initiatives including 5S, visual management, waste reduction, Kaizen events, and continuous improvement activities.
• Identify manufacturing bottlenecks and implement corrective actions to improve flow, ergonomics, quality, and efficiency.
• Develop value stream maps and future-state manufacturing strategies aligned with company growth objectives.
• Support implementation of advanced manufacturing technologies, automation solutions, and digital manufacturing tools.
• Lead root cause investigations and process improvement initiatives across production operations.

Cross-Functional Collaboration

• Partner with Engineering, Manufacturing Engineering, Supply Chain, and Production teams to support Design for Manufacturability (DFM) and operational readiness.
• Support New Product Introduction (NPI) activities by ensuring production systems, layouts, tooling, and labor plans are production-ready.
• Collaborate with Quality and Safety teams to ensure manufacturing operations meet regulatory and company standards.
• Support production ramp planning and operational scaling efforts across multiple aircraft programs.
• Train and mentor technicians, production staff, and junior engineers on industrial engineering best practices and operational excellence methodologies.

Compliance & Documentation

• Develop and maintain manufacturing documentation including process flow diagrams, workstation layouts, labor models, and operational standards.
• Support AS9100 and ISO 9001 compliance initiatives through standardized manufacturing processes and documentation control.
• Maintain accurate production planning and factory layout data within ERP and PLM systems.
• Support manufacturing readiness reviews, operational audits, and process validation activities.

Qualifications:

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering, or related field.
• 5+ years of hands-on industrial engineering or manufacturing engineering experience in aerospace, automotive, defense, or advanced manufacturing industries.
• Experience designing manufacturing floor layouts, production cells, and assembly line workflows.
• Strong understanding of takt time analysis, cycle time studies, line balancing, capacity planning, and labor modeling.
• Experience implementing Lean Manufacturing principles and continuous improvement initiatives.
• Proven experience supporting manufacturing scale-up from prototype or low-rate production into higher-volume operations.
• Strong analytical and problem-solving skills with the ability to make data-driven decisions in fast-paced environments.
• Experience successfully managing multiple high-priority projects simultaneously.
• Strong communication and cross-functional collaboration skills.

Preferred Qualifications:

Aerospace or eVTOL industry experience strongly preferred.
Experience working in startup or rapidly scaling manufacturing environments.
Familiarity with factory simulation and layout tools.
Experience with ERP and PLM systems such as Epicor and Dassault Systems 3DEXPERIENCE (3DX).
Knowledge of AS9100, ISO9001, and aerospace manufacturing standards.
Experience with discrete manufacturing, composites, aircraft assembly, or electromechanical systems.
Lean Six Sigma certification preferred.
Experience supporting production readiness and factory ramp activities.
Interest in advanced air mobility and next-generation aerospace technologies.
Knowledge of FAA Part 103 requirements is a plus.

Soft Skills:

Brings positive attitude and energy to the workplace.
Strong leadership, organizational, and project management capabilities.
Excellent verbal and written communication skills.
Comfortable operating in ambiguous and rapidly evolving environments.
Hands-on problem solver with strong sense of ownership and accountability.
Ability to influence cross-functional teams and drive alignment across organizations.

Attributes aligned with Core Values

Safety Above All: Demonstrates a proactive safety mindset by embedding safety into daily work, identifying and mitigating risks, encouraging open dialogue about safety concerns, and continuously improving practices and protocols.
Customer Focus: Puts customers at the center of every action by understanding their challenges, delivering meaningful value, and supporting their success.
Work Better Together: Seeks and values diverse perspectives, builds cross-functional relationships, and fosters trust through empathetic, fact-based communication and commitment to shared decisions.
Be the Pilot: Drives results with clarity and purpose by focusing on what matters most, adapting to change, taking initiative, and owning outcomes.
Embrace the Unknown: Navigates ambiguity with resilience and bold thinking, challenges the status quo, and combines innovative ideas with practical approaches to overcome obstacles and drive progress.
Respect for People: Fosters a high-performance culture grounded in respect, professionalism, and support by balancing high expectations with a healthy, collaborative environment and being a trusted, dependable teammate.