Director of Manufacturing

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.