Manufacturing Engineering Lead

iCOMAT•Dayton, OH

9d•Onsite

About The Position

ICOMAT is an advanced manufacturing company that invented Rapid Tow Shearing (RTS) - the only proven technology for producing defect-free curved-fiber composite parts at industrial scale. We deliver the lightest structures possible for aerospace, automotive, defense, and space, at a rate and cost efficiency that far exceeds existing composite production processes. We build and operate automated factories for composite materials, delivering components to Tier 1 suppliers and OEMs. The business has three main divisions: development of automated production machines, development of software design and production tools, and operation of the factory. We work with 25+ customers and completed the largest ever Series A in composites manufacturing to fuel a significant scale-up, with growth plans that will see the business multiply in size over the next two to three years and expand operations into the UK, Europe and the US. The business has currently more than 130,000 sqm of production capacity with manufacturing facilities in the UK (Gloucester and Swindon) and the US (Dayton, Ohio); a Hardware R&D Centre in Bristol, UK; and a Software R&D Centre in Athens, Greece. We are seeking an experienced and hands-on Manufacturing Engineering Lead to manage the Manufacturing Engineering and Tooling capability within an iCOMAT plant. Each plant will have an ME Lead responsible for the local ME and Tooling teams. The role will report into the Director of Engineering and work closely with the Operations team. Day-to-day direction will come from Operations, with process standards, technical governance and longer-term strategy coming from Engineering. This is a practical leadership role. The successful candidate will be expected to deliver technical Manufacturing Engineering work content directly, while also managing the team, setting objectives, developing capability and planning the workload. The ideal candidate will bring strong Manufacturing Engineering experience in a production environment. Experience across both composite manufacture and metallic machining/tooling is preferred.

Requirements

Minimum 5 years’ industrial experience within Manufacturing Engineering in a production, NPI or industrialisation environment.
Minimum 3 years’ experience managing, supervising or directly leading a technical team.
Practical knowledge of composite manufacture and processing is essential.
Strong understanding of composite materials and their behavior.
Understanding of AS9100 and quality control within an aerospace or advanced manufacturing environment.
Proficiency in CAD, ideally SolidWorks and Composer, plus Microsoft Word and Excel.
Proven experience leading Manufacturing Engineering, Tooling or production support activity in an industrial environment.
Hands-on approach with the ability to deliver technical work content directly as well as lead others.
Strong understanding of manufacturing process development, production documentation, routings, BoMs, process sheets, work instructions and Methods of Manufacture.
Experience with PFMEA, structured problem solving, root cause analysis, gauge R&R awareness and continuous improvement methods.
Analytical thinking, problem-solving and creativity.
Knowledge of lean manufacturing.
Communication and teamwork skills for cross-functional collaboration.
Ability to plan workload, set objectives, manage priorities and communicate clearly with Operations, Engineering, Quality and Supply Chain stakeholders.
Comfortable working in a fast-moving scale-up environment where processes are being standardised and improved as the business grows.

Nice To Haves

Experience across both composite manufacturing and metallic machining/tooling environments.
Experience of AFP advantageous but not essential.
Knowledge of CNC machining, jigs, fixtures, precision tooling, metallic components and manufacturing cost drivers.
Experience supporting NPI, APQP, production readiness reviews or manufacturing gate reviews.
Experience developing competency frameworks, training matrices and shop-floor training plans.
Degree qualification in Composite Materials, Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering or a related discipline.
Six Sigma Green/Black Belt, advantageous but not essential.

Responsibilities

Lead the plant ME and Tooling teams, setting objectives, developing capability and planning the team workload.
Own the Manufacturing Engineering delivery plan for the plant, ensuring priorities are aligned with Operations and Engineering.
Deliver hands-on Manufacturing Engineering work content as part of the role, not just team management.
Support BD with quotations, including manufacturing methodology, process assumptions, tooling requirements and costings.
Support product design for manufacture as required.
Create routings and BoMs for production and tooling activities.
Create full Methods of Manufacture (MoMs), providing: Step-by-step manufacturing instructions, Health and Safety requirements, including COSHH assessments where required, Tooling required, Equipment required, Key material specifications, Cure cycle specifications and programme numbers, Confirmation that customer specifications, quality approvals and compliance requirements have been identified and covered.
Develop process sheets as required for standard procedures.
Develop and implement quality control procedures and ensure an inspection plan is in place.
Support the Tooling Design team to create tooling concepts, tooling requirements, fixtures and supporting equipment.
Deliver APQP process on NPI where required, including process flow, PFMEA, control plan and PPAP / Fair.
Take build-to-print components, tooling and parts from Design Engineering through to production, ensuring manufacturing risks, process controls and quality requirements have been evaluated.
Own local manufacturing readiness for new products and processes, ensuring process development, tooling, material, documentation, training and quality controls are in place before production release.
Review production data and recommend improvements in quality control and efficiency through process change.
Lead structured problem solving for manufacturing, tooling, quality and process issues, using practical root cause analysis and corrective actions.
Develop plant capability through skills matrices, SME ownership, training plans and help standardised process knowledge across ME, Tooling and Operations.
Support procurement and suppliers with technical guidance on materials, tooling, equipment, packaging and manufacturing requirements.
Promote safe working practices, AS9100-aligned quality standards, lean manufacturing principles and continuous improvement across the plant.
Collaborate across sites to share best practice and help standardise Manufacturing Engineering ways of working as iCOMAT scales internationally.