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A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with…
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Senior Manufacturing/Process Engineer

PROMETHEUS ENERGETICS, LLC
Bloomington, IN

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Job Details

Full-time
6 days ago

Benefits

AD&D insurance
Paid holidays
Disability insurance
Health insurance
Dental insurance
401(k)
Paid time off
Vision insurance

Qualifications

Process flow diagrams
Technical engineering
3D modeling software
Defect resolution root cause analysis
Technical drawing
Procedural guides
PDM software
GD&T
Personal protective equipment (PPE) adherence
Manufacturing standard operating procedures
3D modeling for product design
Manufacturing facility experience
ASME codes & standards
Manufacturing company experience
Failure analysis

Full Job Description

About Prometheus Energetics

Prometheus Energetics is an independent U.S.-based merchant supplier of solid rocket motors and warheads. A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with decades of combat-proven designs, manufacturing know-how, and technical training to deliver field-ready products at scale.

Position Summary

Prometheus Energetics is seeking an experienced Senior Manufacturing & Process Engineer to serve as a critical technical authority as our Bloomington operations transition from facility startup and product industrialization into high-rate production.

In this role, you will bridge product design and shop-floor execution. You will own the manufacturing processes, standard work instructions, production line layouts, and specialized energetic tooling integration required to build tactical solid rocket motors and warheads safely and efficiently. Working closely with Engineering, Operations, Quality, EHS, and strategic partner technology-transfer teams, you will ensure that energetic mixing, casting, curing, machining, and final assembly operations satisfy all technical, quality, safety, and customer performance requirements.

Key Responsibilities

Process Engineering & Shop Floor Integration

Establish, prove out, and sustain manufacturing processes, operational routers, tooling sheets, and detailed Standard Work Instructions (SWIs) for solid rocket motor (SRM) cast/cure, propellant handling, motor assembly, and energetic packaging operations.
Analyze operational flows, workstation ergonomics, and line balance to optimize throughput, reduce cycle times, and support rapid production scaling.
Serve as the primary manufacturing engineering contact for shop-floor operators and technicians, providing real-time troubleshooting, guidance, and technical direction on active production lines.

Tooling Architecture & Capital Equipment

Partner with Tooling Engineers to translate product design requirements and energetic process constraints into robust, safe, and reliable production tooling, molds, fixtures, holding C-frames, and rotation carts.
Define capital equipment specifications, evaluate vendor technical proposals, and manage full-lifecycle acquisition and integration of specialized manufacturing machinery.
Lead on-site equipment installation, proof loading, line buy-off, and operational validation prior to releasing equipment into active energetic production

Non-Conformance, MRB & Continuous Improvement

Act as an active voting member on the Material Review Board (MRB) to evaluate non-conforming hardware, perform engineering dispositions, and implement containment protocols.
Lead formal Root Cause Corrective Action (RCCA) investigations for hardware non-conformances, process escapes, and tooling wear using 5-Why, Fishbone, and 8D methodologies.
Drive continuous improvement and high first-pass yield using Lean/Six Sigma practices, Process Failure Mode and Effects Analysis (PFMEA), Statistical Process Control (SPC), and mistake-proofing (poka-yoke) controls.

Explosive Safety, ESD & Compliance

Partner with Environmental Health & Safety (EHS) and Energetics Safety teams to strictly enforce site-specific explosive safety standards (e.g., DoD 4145.26-M), Electrostatic Discharge (ESD) controls, and OSHA guidelines across all equipment and processes.
Ensure full compliance with AS9100 quality standards, Nadcap requirements, customer drawing specifications, and federal ammunition and explosives regulations.

Performance Management

Establish actionable dashboards, review tooling performance with engineering and operational leadership, and hold owners accountable for recovery and improvement plans. Measures may include:

Process design-to-release schedule compliance and milestone execution
Vendor quality, delivery performance, and technical drawing compliance for equipment and tooling
Process- and tooling-related scrap, rework, cost of poor quality, and first-pass yield impact
Root-cause investigation aging, recurrence prevention, and RCCA effectiveness
Equipment proof-load, calibration, and maintenance plan compliance
Explosive safety, ESD, and ergonomic compliance across all active processing assets
Manufacturing team capability, technical development, and program support effectiveness

Required Qualifications

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related technical discipline.
Minimum of 6+ years of progressive manufacturing, process, or tooling engineering experience in an aerospace and defense hardware manufacturing environment.
Proficiency in 3D CAD software (e.g., PTC Creo, Siemens NX, SolidWorks) and Product Data Management (PDM/PLM) systems (e.g., Windchill).
Solid understanding of Geometric Dimensioning and Tolerancing (GD&T per ASME Y14.5), structural strength of materials, and precision metal fabrication methods.
Proven experience generating assembly routers, process flow diagrams, PFMEAs, and detailed work instructions from complex engineering drawing packages.
Excellent written, verbal, analytical, and executive communication skills.
U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

Master of Science in Mechanical Engineering, Aerospace Engineering, or Engineering Management.
Direct experience in solid rocket motor manufacturing, propellant casting/curing, warheads, pyrotechnics, ammunition, or high-hazard chemical/energetic processing.
Hands-on familiarity with press tooling, hydraulic/pneumatic actuation systems, automated handling carts, and optical/CMM metrology systems.
ASQ certifications (CQE, CQA), formal GD&T certification, or Six Sigma Green/Black Belt credentials.
Prior experience standing up manufacturing lines or integrating new production facilities in a startup or rapid defense expansion environment.
Active U.S. Secret Security Clearance or higher.

Work Environment & Physical Requirements

Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.
Must be able to wear required personal protective equipment (PPE) and comply with site safety, explosive-safety, electrostatic discharge (ESD), and access-control requirements.
Ability to move throughout a manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
Regular, reliable attendance is required. Periodic travel to vendor machine shops, secondary company facilities, or customer sites may be required during startup, tool qualification, or critical production events.

Benefits

Medical, dental, and vision insurance
Life and AD&D insurance; short- and long-term disability coverage
401(k) savings plan
Paid time off and company holidays

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senior manufacturing/process engineer jobs in bloomington, in

Senior Manufacturing/Process Engineer

Senior Manufacturing/Process Engineer (Prometheus Energetics)

Senior Validation Engineer

Senior Supplier Quality Engineer

Automation Engineer

Computer Aided Design (CAD) Designer

Director of Quality (Prometheus Energetics)

Tooling Engineer

Tooling Engineer – Solid Rocket Motor & Energetic Operations (Prometheus)

Process Engineer

Sr. Process Validation Engineer

Sr. Manager, Engineering and Maintenance

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About Prometheus Energetics

Position Summary

Key Responsibilities

Performance Management

Required Qualifications

Preferred Qualifications

Work Environment & Physical Requirements

Benefits

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