Senior Electrical Production Engineer

Overview:

At BlueHalo/AV, we are shaping the future of defense and aerospace systems through innovation, precision, and operational excellence. As a Senior EE/Production Engineer, you will play a pivotal role in enabling high-reliability production through technical leadership, process optimization, and cross-functional collaboration.

Responsibilities:

• Serve as the primary hands-on electrical engineering interface between design and production, supporting the assembly, integration, and test of electrical components, circuit boards, and subsystems across multiple programs.
• Provide day-to-day, on-the-floor technical support for manufacturing, QC, and QA activities, including troubleshooting PCB assemblies, resolving electrical test failures, and driving root cause analysis of yield and performance issues.
• Lead production run support for electrical hardware, ensuring design intent is preserved while enabling high-yield, cost-effective builds across internal and contract manufacturing sites.
• Collaborate with the contract manufacturers and electronic assembly shops to ensure build quality, resolve technical issues, and improve manufacturability of electrical designs.
• Support component sourcing, vendor qualification, and lifecycle management in partnership with procurement and supply chain teams, with emphasis on managing electrical part obsolescence, long lead times, and alternates.
• Maintain and improve electrical manufacturing documentation, including schematics, BOMs, test procedures, and work instructions to ensure consistency across internal teams and external suppliers.
• Coordinate design-for-manufacturability (DFM) and design-for-test (DFT) reviews with R&D and systems engineering teams to ensure smooth transition from prototype to production.
• Lead and support production readiness reviews (PRRs), electrical configuration control, and implementation of engineering change orders (ECOs).
• Track and report key electrical production metrics such as test yields, rework rates, first-pass success rates, and debug cycle times.
• Conduct electrical troubleshooting and rework of subassemblies as needed to support program deadlines and resolve line stoppages or test failures.
• Participate in make/buy analysis specific to electrical assemblies and subsystems, and drive supply chain risk assessments for key electrical components and vendors.
• Contribute to capital equipment planning for electrical test and assembly workstations, as well as facility layout optimizations to improve flow and throughput.
• Mentor junior electrical engineers and technicians, supporting growth of in-house hardware and production engineering capabilities.

Basic Qualifications:

• U.S. citizenship required.
• Eligible for SECRET Security Clearance.
• Bachelor's degree in electrical engineering (or closely related discipline.)
• Minimum 6+ years of hands-on experience in electrical hardware production, electronic subsystem manufacturing, or test engineering.
• Ability to perform soldering work down to 0402 components to support repair of electronics.
• Proficiency with spectrum analyzers, oscilloscopes, VNAs and other electronic measurement equipment.
• Demonstrated ability to work cross-functionally with electrical design, test, manufacturing, supply chain, and quality teams.
• Strong working knowledge of schematics, PCB design, BOM management, and electrical test methods (bench testing, ICT, functional test).
• Proficient in root cause analysis and experienced in lean manufacturing principles relevant to electronic systems.

Preferred Qualifications:

• Active SECRET Security Clearance
• Master's degree in electrical engineering (or a related discipline.)
• Experience in aerospace, defense, or other high-reliability hardware environments.

Salary Range: $95,000 to $110,000

• BlueHalo, an AV company pay range for this job level is a general guideline only and not a guarantee of compensation or salary. Determination of official compensation or salary relies on several factors including, but not limited to, level of position, job responsibilities, geographic location, scope of relevant work experience, educational background, certifications, contract-specific affordability, organizational requirements, alignment with local internal equity as well as alignment with market data.
• Our compensation package also includes components designed to support employees' total well-being, which should be considered when evaluating our competitive benefits package. These benefits include health insurance, life insurance, disability, company holiday and paid time off, parental leave, 401(k) company match and contributions, professional development/training reimbursements, and other work/life programs.