Design for Manufacturing (DFM) Director We are seeking an experienced Design for Manufacturing (DFM) Director to lead the transition of products from development and prototyping into scalable production. This role serves as the bridge between product design, engineering, supply chain, quality, and manufacturing partners to ensure products are optimized for cost, quality, reliability, and manufacturability. The DFM Director will own the process of preparing products for production, establishing manufacturing processes, selecting and managing suppliers, overseeing pilot builds, and driving successful production launch. The ideal candidate combines strong program management and engineering expertise with hands-on manufacturing experience and a proven track record of bringing products from concept to production in support of federal government contracts.
Key Responsibilities
Product Industrialization & Manufacturing Readiness:
Lead the transition of products from prototype and development phases into production.
Evaluate product designs and identify opportunities to improve manufacturability, assembly efficiency, reliability, and cost.
Develop and implement Design for Manufacturing (DFM) and Design for Assembly (DFA) strategies.
Establish manufacturing requirements, production workflows, tooling needs, and process controls.
Collaborate closely with engineering teams to resolve design issues impacting production.
Supplier & Contract Manufacturer Management:
Work with Supply Chain Management to identify, evaluate, and onboard manufacturing partners and suppliers.
Lead or assist in the management of RFQ processes, supplier selection, and manufacturing cost analysis.
Negotiate manufacturing capabilities, production schedules, and quality requirements.
Build strong relationships with contract manufacturers, tooling vendors, and component suppliers.
Develop and drive supplier performance, quality metrics, and delivery schedules.
New Product Introduction (NPI):
Develop and execute NPI plans, timelines, and production readiness milestones.
Assist Program and Engineering Management in leading prototype builds, engineering validation builds, pilot production runs, and production ramp-up activities.
Coordinate cross-functional teams to ensure successful product launch.
Drive issue resolution during pilot and early production phases.
Quality & Process Development:
Assist the Quality Organization in establishing manufacturing quality standards and inspection procedures.
Ensure the development of production documentation including work instructions, assembly procedures, test protocols, and quality plans.
Implement corrective and preventive actions to address production issues.
Support root cause analysis and continuous improvement initiatives.
Cost & Production Optimization:
Develop manufacturing cost models and identify cost reduction opportunities.
Optimize production processes to improve yield, throughput, and efficiency.
Drive value engineering initiatives without compromising product performance or quality.
Support forecasting, capacity planning, and production scaling efforts.
Project Leadership:
Serve as the primary manufacturing lead within cross-functional product teams.
Manage manufacturing readiness schedules and production launch deliverables.
Provide regular updates on production readiness, risks, and mitigation plans.
Ensure alignment between engineering, operations, quality, and supply chain teams.
Qualifications:
RequiredBachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.10+ years of experience in product development, manufacturing engineering, NPI, or production launch roles.
Demonstrated success bringing products from prototype through commercial production.
Strong understanding of DFM, DFA, production processes, and quality systems.
Experience working with suppliers, contract manufacturers, and production partners.
Knowledge of manufacturing methods such as machining, injection molding, sheet metal fabrication, electronics assembly, or other relevant processes.
Experience with BOM management, engineering change control, and production documentation.
Strong project management and cross-functional leadership skills.
Preferred:- Experience in consumer products, industrial equipment, medical devices, electronics, or related manufacturing environments.
- Familiarity with Lean Manufacturing, Six Sigma, APQP, PPAP, FMEA, and quality management systems.
- Experience scaling products from pilot production to volume manufacturing.
- PMP, Lean, or Six Sigma certification.
- Key Performance Indicators (KPIs)
- On-time production launch
- Manufacturing cost targets achieved
- Production yield and quality metrics
- Supplier readiness and performance
- Successful completion of pilot builds
- Time-to-production milestones
- Product reliability and field performance
- Continuous improvement and cost reduction achievements
Success in This RoleWithin the first year, the DFM Director will establish manufacturing readiness processes, successfully launch products into production, develop a robust supplier network, implement scalable manufacturing systems, and ensure products meet quality, cost, and delivery objectives. Marathon TS is committed to the development of a creative, diverse and inclusive work environment. In order to provide equal employment and advancement opportunities to all individuals, employment decisions at Marathon TS will be based on merit, qualifications, and abilities. Marathon TS does not discriminate against any person because of race, color, creed, religion, sex, national origin, disability, age or any other characteristic protected by law (referred to as "protected status").
