Aerospace Manufacturing/Industrial Lead

Overview

Expleo Group USA is seeking experienced Aerospace Manufacturing / Industrial Leads to support current aerospace, defense, advanced manufacturing, and industrial operations programs in Washington, DC

This role focuses on manufacturing process optimization, Lean transformation, operational excellence, takt and cycle time analysis, capacity planning, and continuous improvement initiatives designed to drive production efficiency, quality, and operational performance.

Responsibilities:

Manufacturing Operations & Process Optimization

• Analyze and improve manufacturing workflows to maximize productivity, quality, safety, and operational efficiency.
• Lead shop floor process optimization initiatives focused on bottleneck identification, throughput improvement, and operational performance.
• Develop, implement, and maintain standardized work instructions, operational procedures, and best practices.
• Drive capacity planning activities to support current production requirements and future growth objectives.
• Support new product introduction (NPI), production ramp-ups, and manufacturing readiness initiatives.
• Collaborate closely with Production, Manufacturing Engineering, Quality, and Operations teams to optimize manufacturing flow.
• Develop and maintain production performance metrics, operational dashboards, and KPI reporting systems.

Lean Manufacturing & Continuous Improvement

• Serve as the site subject matter expert for Lean Manufacturing principles and methodologies.
• Lead Kaizen events, Continuous Improvement initiatives, and operational excellence projects.
• Facilitate root cause investigations and corrective action implementation.
• Drive implementation and sustainment of Lean principles, including: Value Stream Mapping, Standard Work, Waste Elimination, Flow Manufacturing, Visual Management, Error Proofing (Poka-Yoke), Daily Management Systems
• Apply structured problem-solving methodologies, including: A3 Thinking, PDCA (Plan-Do-Check-Act), 5 Why Analysis, Fishbone Diagram Analysis
• Identify and implement productivity improvement opportunities across manufacturing operations.

Takt Time & Cycle Time Analysis

• Conduct detailed takt time, cycle time, and work measurement studies across manufacturing operations.
• Evaluate production flow and identify opportunities to balance workloads and eliminate inefficiencies.
• Develop labor utilization models, line balancing strategies, and workforce productivity plans.
• Recommend process improvements that support production targets while maintaining quality standards.
• Utilize data-driven decision-making to support operational and manufacturing improvements.
• Analyze production performance data and develop actionable recommendations for leadership.

5S & Visual Management Systems

• Establish and sustain world-class 5S programs throughout manufacturing operations.
• Design and implement effective visual management systems that improve communication, workflow visibility, and shop floor performance.
• Develop visual controls, KPI boards, production tracking systems, and operational dashboards.
• Conduct routine audits and assessments to ensure compliance with Lean standards and continuous improvement objectives.
• Support the development of a culture focused on operational discipline and workplace organization.

Cross-Functional Leadership & Collaboration

• Partner with Manufacturing Engineering, Industrial Engineering, Production, Quality, Supply Chain, Operations, and Program Management teams.
• Support implementation of corrective and preventive actions related to manufacturing performance and quality metrics.
• Mentor supervisors, manufacturing leads, and production personnel on Lean methodologies and continuous improvement practices.
• Present improvement roadmaps, KPI results, and project updates to leadership teams and customer stakeholders.
• Foster a culture of accountability, operational excellence, and continuous improvement across manufacturing operations.
• Lead cross-functional initiatives that improve safety, quality, delivery, and cost performance.

Qualifications

• Bachelor's Degree in Industrial Engineering, Manufacturing Engineering, Operations Management, or a related technical discipline.
• Equivalent combination of education and significant manufacturing experience may be considered.
• 10+ years of manufacturing, industrial engineering, operational excellence, or related experience.
• Experience leading Lean Manufacturing initiatives within a production environment.
• Demonstrated experience conducting takt time studies, cycle time analysis, work measurement, and line balancing activities.
• Strong understanding of manufacturing processes, production flow optimization, and operational performance improvement.
• Experience implementing and sustaining 5S programs and Visual Management Systems.
• Proficiency utilizing manufacturing KPIs, performance metrics, and operational dashboards.
• Strong analytical, problem-solving, and data-driven decision-making skills.
• Excellent communication, leadership, and stakeholder management abilities.
• Ability to operate effectively within a fast-paced manufacturing environment.
• Experience driving continuous improvement and operational excellence programs.
• Aerospace, aviation, unmanned systems, defense, or advanced manufacturing industry experience.
• Industrial Engineering background with hands-on manufacturing support experience.
• Lean Six Sigma Green Belt or Black Belt certification.
• Experience supporting composite manufacturing, aerospace assembly operations, or fabrication environments.
• Familiarity with production planning, labor modeling, and work measurement techniques.
• Experience utilizing ERP, MES, or manufacturing data systems.
• Project management experience leading cross-functional improvement initiatives.
• Knowledge of AS9100 and aerospace quality requirements.
• Experience supporting Airbus or other aerospace OEM manufacturing programs.

What We Offer

At Expleo Group USA, we value expertise, innovation, and collaboration. By joining our client's team, you'll support industry-leading manufacturing and aerospace programs while working in a highly collaborative environment focused on operational excellence and continuous improvement.

• Competitive Compensation – Up to $175,000 annually or $85/hourly. Final compensation will be determined based on the role, skill alignment, years of experience, and fair, market-based rates by geography.
• Comprehensive Benefits for You and Your Dependents – Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short/Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with matching.
• Paid Holidays and Paid Time Off
• Career Development and Advancement – Expleo is a global company operating in 29 countries with a strong focus on professional development.
• Strong Team Culture – Collaborate with experienced professionals who value operational excellence, innovation, continuous improvement, and teamwork.

This position may require access to information subject to U.S. export control regulations (e.g., ITAR/EAR). Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to "U.S. Persons," including U.S. citizens, lawful permanent residents (green card holders), and individuals granted refugee or asylee status.

Expleo is a trusted partner for end-to-end, integrated engineering, quality services, and management consulting for digital transformation. We are a talent incubator. The time you spend at Expleo will turbocharge your career, allowing you to work on complex technical challenges, expand your skills, and participate in inspiring multidisciplinary collaborations. Whether working on advanced aerospace programs, next-generation manufacturing operations, or operational excellence initiatives, you'll have the opportunity to become a bolder version of yourself. Let's change the game together.

Expleo is an equal opportunity employer. We are committed to non-discrimination in all stages of the recruitment process, ensuring fair and unbiased hiring practices. We evaluate qualified applicants without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, or any other protected characteristic under applicable laws.

Benefits

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