Design for Manufacturing Director

This is an excellent opportunity for a manufacturing leader with extensive experience supporting federal government programs who thrives in fast-paced, highly technical environments. The position is hybrid, with primary locations in Lorton, VA and Franklin, MA, and requires approximately 40% travel between both sites.

• Lead the transition of products from prototype and development into scalable, full-rate production.
• Drive Design for Manufacturing (DFM) and Design for Assembly (DFA) initiatives to improve manufacturability, production efficiency, quality, reliability, and cost.
• Establish manufacturing readiness strategies, production processes, tooling requirements, process controls, and production documentation.
• Partner closely with engineering teams to identify and resolve design issues impacting manufacturing and production.
• Lead manufacturing readiness efforts for multiple federal government programs, including immediate support for critical Army programs.
• Develop and execute New Product Introduction (NPI) plans, production launch schedules, pilot builds, engineering validation builds, and production ramp-up activities.
• Collaborate with Supply Chain and Procurement teams to evaluate, qualify, and manage suppliers, contract manufacturers, and production partners.
• Support supplier selection, manufacturing cost analysis, production scheduling, and supplier performance management.
• Assist Quality teams in developing manufacturing quality standards, inspection procedures, work instructions, assembly documentation, and testing protocols.
• Drive continuous improvement initiatives focused on production efficiency, yield, throughput, quality, and cost reduction.
• Support engineering change management, BOM management, production documentation, and manufacturing process improvements.
• Lead cross-functional manufacturing readiness reviews, communicate project status, identify risks, and implement mitigation strategies.
• Provide technical leadership and subject matter expertise while effectively communicating with executive leadership, engineering teams, manufacturing personnel, suppliers, and government stakeholders.
• Support forecasting, production capacity planning, and long-term manufacturing scalability.

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical discipline.
• 10+ years of experience in manufacturing engineering, product development, New Product Introduction (NPI), production launch, or Design for Manufacturing leadership.
• Demonstrated success transitioning products from prototype through pilot production into full-rate manufacturing.
• Required experience supporting federal government or defense-related programs.
• Strong knowledge of Design for Manufacturing (DFM), Design for Assembly (DFA), manufacturing readiness, production planning, and quality systems.
• Experience working with suppliers, contract manufacturers, and complex manufacturing supply chains.
• Knowledge of manufacturing processes such as machining, sheet metal fabrication, electronics assembly, injection molding, or related production methods.
• Experience with engineering change control, BOM management, manufacturing documentation, and production process development.
• Strong project management skills with the ability to lead cross-functional teams and manage multiple priorities.
• Excellent communication and leadership skills with the ability to influence stakeholders at all organizational levels.
• Flexible, collaborative, and able to serve as the organization's subject matter expert for manufacturing readiness and production transition.

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This job is Hybrid Remote.

We offer several comprehensive benefits package including health and life insurance, paid and unpaid time off, and retirement and savings plans to qualifying employees.

Download the Sparks Group mobile app from Apple App Store or Google Play.

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Sparks Group is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, pregnancy, citizenship, family status, genetic information, disability, or protect veteran status.