Director of Manufacturing
Position Summary
The Director of Manufacturing oversees all manufacturing operations for a high-growth non-lethal defense company. This leader is responsible for scaling production, ensuring the highest levels of product reliability, and maintaining strict adherence to safety, compliance, and quality standards specific to non-lethal technologies. The Director of Manufacturing will drive operational excellence, oversee production environments, partner closely with R&D, and ensure the consistent delivery of life-saving, mission-critical products used by consumers, law enforcement, and security professionals worldwide.
Key Responsibilities
Strategic Leadership
- Develop and execute a multi-year manufacturing strategy that supports rapid growth and increasing global demand for non-lethal defense products.
- Forecast capacity needs based on new product rollouts, regulatory shifts, and market expansion.
- Integrate advanced manufacturing technologies, automation, and testing systems tailored for precision-based non-lethal devices.
Manufacturing Operations
- Lead day-to-day operations across production lines including launchers, ammunition, accessories, and wearable technologies.
- Ensure manufacturing processes achieve optimal cycle time, OEE, takt time, and reliability.
- Implement standardized operating procedures that guarantee consistent product performance in field conditions.
Compliance, Quality & Safety
- Maintain compliance with federal and international regulatory bodies relevant to non-lethal weapons and safety equipment.
- Ensure rigorous quality management practices including proof testing, ballistics validation, and reliability checks.
- Cultivate a culture where product safety, trust, and quality assurance remain top priorities.
Leadership & Talent Development
- Build, lead, and develop high-performing engineering, manufacturing, and plant leadership teams.
- Establish training and certification programs for technicians handling specialty materials and precision components.
- Drive succession planning to support organizational scaling.
Product Launch & Engineering Integration
- Partner closely with R&D and Product Engineering to transition new platforms from prototype to full-scale production.
- Lead DFM efforts to ensure new products meet cost, manufacturability, durability, and reliability standards.
- Oversee validation builds, pilot runs, and ramp-ups for new technologies.
- Continuous Improvement & Lean Systems
- Champion Lean, Six Sigma, and CI to reduce scrap, increase throughput, and enhance reliability.
- Implement automation strategies to improve consistency and reduce variation.
- Embed statistical process controls and root-cause analysis for performance improvement.
Supply Chain & Materials Management
- Collaborate with Supply Chain to secure critical components such as chemical agents, projectiles, electronics, and proprietary polymers.
- Ensure vendor alignment with defense-grade quality, dual-sourcing, and risk mitigation.
- Optimize inventory and ensure continuity of supply.
Financial & Cost Management
- Oversee budgets, labor strategy, and plant P&L.
- Lead cost-reduction initiatives while maintaining product reliability.
- Drive capital investment planning for automation and facility expansion.
Qualifications
Education & Experience
- Bachelor’s degree in Engineering, Manufacturing, Operations, or related field (Master’s preferred).
- 12–15+ years of leadership in defense, non-lethal technologies, weapons systems, ammunition, or regulated manufacturing.
- Proven success scaling production for safety-critical or mission-critical products.
Skills & Competencies
- Strong knowledge of mechanical, pneumatic, chemical, and electronic manufacturing processes.
- Expertise in Lean, Six Sigma, and operational excellence.
- High analytical and financial acumen.
- Strong leadership presence and ability to influence.
- Ability to navigate regulated environments.
Success Indicators
- Increased throughput while improving safety and reliability.
- Successful new product introductions.
- Reduced scrap, rework, and field failures.
- Strengthened supply chain resilience.
- Development of a high-performance manufacturing culture.
- Achievement of cost and operational targets.
