Module Manufacturing Engineer

Expleo•Washington, DC, DC

7d•$53 - $110,000

About The Position

We are growing our network of experienced Module Manufacturing Engineers to support current and upcoming aerospace programs focused on composite manufacturing, aircraft assembly, manufacturing process development, tooling design, production readiness, and operational excellence.

Requirements

Bachelor's Degree in Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering, Industrial Engineering, or a related technical discipline.
Equivalent combination of education and significant aerospace manufacturing experience may be considered.
8+ years of manufacturing engineering experience within aerospace, aviation, defense, or advanced manufacturing environments.
Experience developing manufacturing work orders, work instructions, routers, travelers, and production process documentation.
Strong background in composite manufacturing processes, materials, and fabrication techniques.
Experience supporting aerospace assembly operations and production environments.
Experience designing manufacturing tooling, assembly fixtures, and composite layup tooling.
Ability to interpret engineering drawings, specifications, and 3D CAD models.
Strong process improvement, troubleshooting, and problem-solving capabilities.
Excellent communication and cross-functional collaboration skills.
Ability to work effectively in a fast-paced aerospace manufacturing environment.
Experience supporting UAV, UAS, or autonomous aircraft programs.
Experience conducting or supporting PFMEA (Process Failure Mode and Effects Analysis) activities.
Knowledge of Lean Manufacturing and Continuous Improvement methodologies.
Familiarity with AS9100 and aerospace quality management systems.
Experience supporting prototype development, low-rate production, and production ramp-up efforts.
Knowledge of composite curing, bonding, trimming, and structural assembly processes.
Experience utilizing Manufacturing Execution Systems (MES), ERP systems, and production planning tools.
Understanding of aircraft structures, tooling validation, and manufacturing readiness requirements.
Experience supporting Airbus aerospace programs or advanced aerospace manufacturing environments.

Responsibilities

Develop and implement manufacturing processes for composite structures, subassemblies, and final aircraft assembly operations.
Support prototype, low-rate initial production (LRIP), and full-rate manufacturing activities.
Evaluate manufacturing methods and identify opportunities for process improvement, cost reduction, and productivity enhancement.
Ensure manufacturing processes meet quality, safety, and production requirements.
Collaborate with Design Engineering teams to ensure products are optimized for manufacturability and efficient production.
Support manufacturing readiness activities throughout the product lifecycle.
Create and maintain detailed manufacturing work orders, routers, travelers, and shop floor documentation.
Develop clear, accurate, and repeatable work instructions for composite fabrication and assembly operations.
Translate engineering drawings, CAD models, and specifications into production-ready manufacturing processes.
Support engineering change implementation and configuration management activities.
Provide technical guidance and process documentation to manufacturing personnel.
Ensure manufacturing documentation aligns with customer, regulatory, and aerospace requirements.
Develop manufacturing methods and procedures for composite layup, bonding, trimming, curing, and assembly operations.
Support production teams in executing composite fabrication activities while maintaining quality and schedule objectives.
Evaluate manufacturing challenges and implement corrective actions to improve process capability and product quality.
Partner with Quality teams to resolve nonconformances and improve first-pass yield performance.
Assist in transitioning products from development and prototype phases into production environments.
Support continuous improvement of composite manufacturing processes and best practices.
Define, develop, and optimize aircraft assembly processes for structures, modules, and integrated systems.
Support assembly sequencing, work package development, and production planning activities.
Participate in manufacturing readiness reviews and production build planning efforts.
Collaborate with production teams to troubleshoot assembly issues and improve production flow.
Drive process standardization and implementation of assembly best practices.
Support production ramp-up activities and operational performance improvements.
Design and develop manufacturing tooling, assembly fixtures, and composite layup aids.
Support tooling requirements throughout product development and the production lifecycle.
Evaluate tooling effectiveness and implement enhancements to improve quality, safety, and efficiency.
Collaborate with Manufacturing, Design, and Quality teams to ensure tooling solutions support production objectives.
Manage tooling modifications, maintenance requirements, and continuous improvement initiatives.
Support tooling validation and production readiness assessments.
Lead manufacturing process improvement initiatives focused on quality, cost, delivery, and operational efficiency.
Apply Lean Manufacturing principles to reduce waste and improve shop floor performance.
Participate in root cause investigations and corrective action implementation activities.
Support process validation efforts and manufacturing readiness assessments.
Contribute to production KPI development, reporting, and performance monitoring.
Drive continuous improvement initiatives that support operational excellence and manufacturing maturity.