Director of Manufacturing

Director of Manufacturing Position SummaryThe 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 ResponsibilitiesStrategic LeadershipDevelop 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 OperationsLead 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 & SafetyMaintain 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 DevelopmentBuild, 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 IntegrationPartner 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 SystemsChampion 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 ManagementCollaborate 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 ManagementOversee budgets, labor strategy, and plant P&L.Lead cost-reduction initiatives while maintaining product reliability.Drive capital investment planning for automation and facility expansion.QualificationsEducation & ExperienceBachelor’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 & CompetenciesStrong 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 IndicatorsIncreased 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.