Process Engineer, Service Tooling & Processes

Zipline is the world’s largest and most experienced autonomous delivery service, founded to serve all humans equally by ensuring access to essential goods anytime, anywhere. We design, build, and operate the world’s largest autonomous logistics system, delivering critical supplies quickly and reliably. Today, Zipline operates on four continents, makes a delivery somewhere in the world every 30 seconds, and has completed millions of deliveries including blood, vaccines, medical supplies, food, and commercial products. Our customers include healthcare systems, governments, retailers, and global brands who rely on us to save lives, reduce emissions, increase economic opportunity, and provide new logistics services at scale.

Our technology goes beyond drones. We deploy integrated logistics infrastructure that strengthens supply chains, reduces congestion, and enables instant delivery, transforming how essential goods reach people everywhere. With more than 140 million commercial autonomous miles safely flown, Zipline is redefining access to healthcare, consumer products, and food across the globe.

We operate at a global scale and are looking for practical problem solvers who thrive on real-world challenges and rapid growth. Our team is motivated by building systems that have a direct, meaningful impact on people’s lives and by scaling the future of logistics.

About You and The Role  

As a Process Engineer on the Service Tooling & Processes team, you will design, validate, and optimize the workflows that enable Zipline’s technicians to maintain the P2 fleet safely, consistently, and efficiently. You’ll translate engineering intent into scalable processes, implement lean methodologies, and ensure that service procedures are robust enough for diverse operating environments. This role is highly cross-functional, bridging engineering, maintenance, and operations, so that every maintenance action contributes to safety, reliability, and fleet health.

What You'll Do  

• Design, document, and refine standardized maintenance processes, from inspections and servicing to component replacements and complex repairs.
• Validate processes in the field through pilots and technician feedback, ensuring usability, repeatability, and safety.
• Collaborate with Hardware Engineering, Reliability, and Tooling teams to align process design with aircraft and service architecture.
• Apply lean principles, error-proofing mechanisms, and automation opportunities to improve efficiency and reduce variability.
• Establish process control mechanisms and ensure compliance with safety and regulatory standards.
• Create process documentation, work instructions, and visual aids that enable frontline technicians to execute tasks consistently.
• Partner with Data and Reliability teams to define KPIs, track performance, and identify opportunities for continuous improvement.
• Lead root cause investigations for process-related issues and implement corrective/preventive actions.
• Provide structured feedback loops to engineering on design-for-maintainability.
• Partner with training program leadership to ensure process changes are embedded into training programs for technicians.

What You'll Bring 

• 4-6 years of experience in mechanical or mechatronic design, ideally in aerospace, automotive, or industrial tooling.
• Proficiency with CAD software (SolidWorks, CATIA, or similar).
• Strong understanding of manufacturing processes (CNC, additive manufacturing, machining, etc.).
• Experience with GD&T and technical drawing best practices.
• Ability to collaborate cross-functionally and communicate technical solutions clearly.
• Strong problem-solving mindset and attention to detail.
• Passion for Zipline’s mission and enabling frontline operators through world-class processes.
• Willingness to travel up to 50%.

What Else You Need to Know   

The starting cash range for this role is $160,000 - $170,000. Please note that this is a target, starting cash range for a candidate who meets the minimum qualifications for this role. The final cash pay for this role will depend on a variety of factors, including a specific candidate's experience, qualifications, skills, working location, and projected impact. The total compensation package for this role may also include: equity compensation; discretionary annual or performance bonuses; sales incentives; benefits such as medical, dental and vision insurance; paid time off; and more.