Job Descriptions:
GENERAL JOB SUMMARY:
The Manufacturing / Process Engineer is responsible for developing, improving, controlling, and supporting manufacturing and assembly processes used to produce TDI turbine engines, engine accessories, subassemblies, and related aerospace products.
This role provides direct technical support to production personnel and serves as a primary problem-solving resource for manufacturing, quality, supplier, tooling, equipment, and process-related issues. The Manufacturing / Process Engineer is expected to work primarily where the work is performed, rapidly contain production issues, determine root cause, implement sustainable corrective actions, and verify that improvements are effective.
The position works cross-functionally with Operations, Engineering, Quality, Supply Chain, Configuration Management, Program Management, Test, and suppliers to ensure manufacturing processes are safe, repeatable, capable, properly documented, and aligned with customer, engineering, quality, cost, and delivery requirements.
ESSENTIAL JOB FUNCTIONS
Manufacturing Process Development
Develop, document, implement, and maintain manufacturing, assembly, inspection, test, and material-handling processes.
Convert engineering drawings, specifications, bills of material, and customer requirements into practical and repeatable manufacturing processes.
Develop and maintain manufacturing work instructions, routers, travelers, visual aids, standard work, process flow diagrams, and supporting documentation.
Establish the proper sequence of operations, tooling requirements, inspection points, labor content, process controls, and acceptance criteria.
Support the transition of new products from engineering development and prototype builds into controlled production.
Participate in manufacturing readiness, producibility, design-for-manufacturability, and design-for-assembly reviews.
Identify special processes, critical characteristics, key characteristics, and required process controls.
Ensure processes are released and controlled through applicable configuration management, Engineering Change Order, and Change Control Board processes.
Structured Problem Solving
Lead and facilitate structured problem-solving activities involving manufacturing, assembly, test, inspection, equipment, tooling, supplier, and product-performance issues.
Respond quickly to production disruptions and establish immediate containment actions to protect employees, customers, product quality, and delivery commitments.
Apply structured problem-solving methods and tools such as:
5 Why analysis
8D problem solving
DMAIC
Lean
DFSS
Shainin RedX
Statistical analysis
Designed of experiments
Is/Is Not analysis
Pareto analysis
Process mapping
Fault-tree analysis
Cause-and-effect analysis
Separate symptoms from verified root causes and avoid implementing unsupported or temporary solutions as permanent corrective actions.
Develop corrective and preventive actions with clearly assigned owners, completion dates, success criteria, and effectiveness-verification plans.
Support and participate in nonconformance reports, corrective action requests, failure investigations, material review activities, and root-cause corrective-action reviews.
Use factual evidence, process data, inspection results, test results, and direct observation to validate conclusions.
Document lessons learned and ensure improvements are incorporated into procedures, travelers, training, tooling, drawings, PFMEAs, control plans, and standard work.
Production Support
Provide responsive, hands-on engineering support to technicians, inspectors, test personnel, and production leadership.
Evaluate production issues at the point of occurrence and help determine whether work should continue, stop, be contained, or be escalated.
Support engine assembly, subassembly, machining, balancing, inspection, test, teardown, repair, and rework activities.
Develop technically sound repair and rework instructions in coordination with Engineering, Quality, and Configuration Management.
Identify production constraints, process bottlenecks, excessive queue time, rework, scrap, and other barriers to flow.
Support daily production meetings, shop-floor reviews, manufacturing readiness reviews, and schedule-recovery activities.
Assist with work-center layout, material presentation, kitting, point-of-use tooling, workstation design, and ergonomic improvements.
Provide technical guidance while respecting approved engineering, quality, customer, and configuration requirements.
Continuous Improvement and Process Capability
Lead continuous-improvement activities focused on safety, quality, delivery, cost, productivity, and employee effectiveness.
Establish process baselines and measure performance using appropriate operational and quality metrics.
Improve process capability, repeatability, flow, first-pass yield, cycle time, labor efficiency, throughput, and equipment utilization.
Conduct time studies and establish realistic process times, labor standards, staffing assumptions, and capacity requirements.
Support line balancing, takt-time analysis, standard work combination, workload distribution, and capacity planning.
Apply Lean manufacturing principles, including:
Standard work
Workplace organization and 6S
Visual management
Waste reduction
Error proofing
Setup reduction
Cellular flow
Pull systems
Point-of-use material
Use statistical process control and capability analysis when appropriate to identify variation and maintain process control.
Establish measurable performance expectations and verify that improvements are sustained after implementation.
Tooling, Equipment, and Facility Support
Define technical requirements for production tooling, fixtures, gauges, equipment, and manufacturing systems.
Design or coordinate the design of fixtures, assembly aids, error-proofing devices, test equipment, and material-handling solutions.
Develop equipment and tooling specifications, business justifications, cost estimates, and implementation plans.
Support supplier selection, equipment acceptance, installation, commissioning, qualification, and operator training.
Establish preventive-maintenance, calibration, inspection, and verification requirements for manufacturing equipment and tooling.
Investigate equipment-related failures and coordinate repairs, upgrades, or replacement actions.
Ensure equipment and tooling changes are documented and approved before production use.
Quality and Compliance
Support compliance with AS9100, customer requirements, engineering specifications, internal procedures, and applicable regulatory requirements.
Participate in PFMEA development and maintenance, control-plan creation, inspection-planning, and process risk assessments.
Support First Article Inspection, production part approval, source inspection, and customer-readiness activities as required.
Assist Quality with nonconformance disposition, defect prevention, inspection planning, measurement-system analysis, and corrective action.
Help establish clear in-process and final inspection criteria.
Ensure manufacturing documentation accurately reflects the approved process and current engineering configuration.
Support internal, customer, and regulatory audits by providing objective evidence of process control and corrective-action effectiveness.
Promote strict adherence to product traceability, foreign-object-debris prevention, material control, ESD controls, and configuration requirements.
New Product Introduction and Production Readiness
Support new-product introduction from design concept through prototype, qualification, low-rate production, and full-rate production.
Participate in design reviews, manufacturing-readiness assessments, build-readiness revie
