Build Specialist, Barrel Production (Starship)

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)