Senior Manufacturing Process Flow & Control DFX Engineer (Subsystem) — TeraWave Operation at Blue Origin in Bay Area, CA

Job description

Application close date: Applications will be accepted on an ongoing basis until the requisition is closed. At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight! This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities. Blue Origin's Emerging Systems business unit is building TeraWave, a satellite communications constellation powered by the most advanced optical communications architecture ever attempted: thousands of optically interconnected satellites delivering symmetrical data speeds of up to 6 Tbps anywhere on Earth, providing enterprise and hyperscale customers with resilient, scalable connectivity for critical operations where terrestrial infrastructure cannot reach. As a Senior Manufacturing Process Flow & Control DFX Engineer (Subsystem), you will own the end-to-end manufacturing process flow and process control design integration at the subsystem level for TeraWave production — bridging subsystem-level production line architecture, process control systems, and volume production readiness. As a foundational element of TeraWave operations, subsystems must be produced through process flows architected not only for throughput but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, optimized, and scaled complex subsystem-level manufacturing process flows and control systems in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale. Special Mentions: Relocation assistance is available for qualified candidates. Travel: Up to 50%. Responsibilities: Subsystem Process Flow & Control Design, Integration & Manufacturing Lead subsystem-level manufacturing process flow design across satellite subsystems: subsystem production line architecture, inter-station workflow sequencing, subassembly integration points, takt time optimization, and material flow between subsystem builds. Own subsystem process control development — including statistical process control (SPC), process monitoring, traveler and work instruction systems, MES integration, and data collection workflows across subsystem boundaries — to ensure robust, repeatable production. Manage subsystem-level process documentation, routing definition, capacity planning, cross-subsystem coordination, and production line oversight. Drive subsystem process validation, control plan development, first-article and production readiness reviews to support production ramp. Design for Excellence (DFX) Drive Design for Excellence (DFX) principles — DFM, DFT, DFA, DFR, and DFS — across the full subsystem-level manufacturing process flow and control lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations. Design for Manufacturability (DFM): Optimize subsystem process sequencing, station layout, and cross-subsystem workflow to maximize yield, throughput, and minimize cost at constellation-scale production volumes. Design for Test (DFT): Architect subsystem-level in-line test and inspection points, data capture, and process monitoring to enable efficient subassembly acceptance, traceability, and in-field diagnostics. Design for Assembly (DFA): Simplify subsystem process steps, minimize handoffs between subsystem builds, and optimize integration points to reduce cycle time, rework, and error rates. Design for Reliability (DFR): Apply process FMEA, control plans, statistical process control, and reliability prediction to ensure consistent, defec