Manufacturing Engineer IV - Motor Windings

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!

As a member of the Blue Origin family of companies, Honeybee Robotics has been at the forefront of robotics for over 40 years. Our Colorado location specializes in creating advanced motion control solutions for NASA, defense, and commercial programs. Our work has played a critical role in thousands of projects, spanning from conceptual design studies to flight missions, including NASA's Artemis I Mission and the Roman Space Telescope. We are seeking technically brilliant individuals who are passionate about their work, thrive in collaborative environments, and have a laser focus on the details that drive excellence.

• •Relocation provided
• •Shift: Monday–Friday (5/8 schedule)
• •Interviews will include a technical assessment

General

• •Lead new product integration for motor winding products, partnering with design engineering from concept through production release to ensure designs are manufacturable, scalable, and cost-effective
• •Develop, validate, and document winding processes (e.g., needle, flyer, linear, or insertion winding, hairpin or form-wound coils, lead dressing and termination, lacing, insulation systems, varnish/VPI, potting, and bonding)
• •Define process parameters, develop process flows, and perform process capability studies (e.g., DOE, SPC, Cpk, MSA) to establish robust, repeatable processes
• •Specify, design, and qualify winding equipment, fixtures, tooling, and ground support equipment (GSE), including semi-automated and automated solutions that improve quality, throughput, and yield
• •Develop comprehensive production process documentation, including routings, work instructions, process control plans, and PFMEAs
• •Define and implement in-process and end-of-line electrical test methods for windings, such as resistance, inductance, insulation resistance, hipot, surge, and partial discharge testing
• •Provide hands-on support to the technician team for prompt resolution of issues in a fast-paced production environment
• •Lead troubleshooting and disposition of non-conforming (NC) winding and motor hardware through detailed work instructions
• •Drive isolation, containment, and resolution of NC parts and assemblies
• •Lead root cause analysis (RCA) and root cause corrective actions (RC/CA) to prevent recurrence of manufacturing and hardware issues
• •Apply lean manufacturing and continuous improvement methods to reduce scrap, rework, and cycle time
• •Support design and operational gated reviews by contributing to required technical artifacts and readiness assessments
• •Collaborate with design engineering to implement Engineering Change Requests (CRs) that improve manufacturability and reduce non-conformances
• •Partner with design teams early in the development cycle to improve Design for Manufacture and Assembly (DFMA) prior to design release
• •Work with suppliers on materials, magnet wire, insulation systems, and outsourced winding processes as needed