Senior Manufacturing & Process Engineer

Enjet Aero•Malden, MA

About The Position

The Senior Manufacturing & Process Engineer (Sheet Metal & Fabrication) develops, documents, and continuously improves processes for forming, welding, and assembling complex sheet metal jet engine components and assemblies. The role owns the process from blank development through forming, welding, heat treat, and final assembly, using production and inspection data to improve quality, yield, and on-time delivery. The position is intended for a seasoned, hands-on engineer who can turn customer prints into stable, well-documented, repeatable processes. The engineer determines process methodology and routing; develops and qualifies forming and welding processes; creates shop-floor manufacturing documentation; designs or oversees the build of tooling and fixtures; analyzes process and inspection data; leads corrective-action investigations; troubleshoots production issues; interprets customer drawings and requirements; supports special processes; collaborates with Quality, Production, Programming, and the Toolroom; trains operators; and drives Lean continuous improvement.

Requirements

At least 10 years of experience as a manufacturing, process, or fabrication engineer in an aerospace or similar precision sheet metal environment; jet engine component experience is strongly preferred.
Bachelor’s degree in Mechanical, Manufacturing, or Welding Engineering, or an equivalent combination of education and hands-on experience.
Extensive hands-on experience with sheet metal forming and fabrication, including flat pattern and blank development, bend allowance, springback, forming limits, press brake forming, rolling, and hydroforming.
Strong working knowledge of welding processes and weld fixturing, including TIG (GTAW), resistance spot, and resistance seam welding; weld joint design, distortion control, and fixture, backing, and purge design.
A proven track record of taking a part from print to a stable, documented, repeatable process.
Ability to write clear, accurate work instructions, process sheets, and engineering reports.
Hands-on experience leading root cause and corrective action investigations and implementing permanent fixes.
Ability to diagnose forming, welding, and assembly problems at the machine and drive process improvements.
Experience using SPC, inspection data, and yield or scrap metrics to drive process changes.
Knowledge of metal types and how they form and weld, including High Nickel Alloys (Inconel 625/718, Hastelloy X), Titanium, and Aluminum, and the effects of heat treat and stress relief.
Strong blueprint-reading and GD&T skills.
Ability to communicate effectively and efficiently with all levels of the organization.
Ability to collaborate in a team environment.
Ability to travel as required for training.

Nice To Haves

Siemens NX modeling and drafting experience.
Experience with expanding, roll forming, and metal spinning.
Assembly and riveting experience, including solid and blind rivets.
Fixture design and toolmaking experience.
Knowledge of manual machining, including mills and lathes.
Knowledge of laser fixture design and laser processing.
CNC programming knowledge (G and M code, NX CAM) and/or laser programming.
Experience working within an AS9100 quality management system.
Working knowledge of aerospace standards and special processes, including welding, heat treat, and NDT.
Experience working to jet engine OEM specifications, such as GE Aerospace, Pratt & Whitney, Rolls-Royce, or Honeywell.
Lean Manufacturing and/or Six Sigma training or certification.

Responsibilities

Determine methodology and process routing for sheet metal details, welded assemblies, and riveted assemblies, from flat pattern and blank development through laser cutting, forming, welding, machining, heat treat, and final inspection.
Develop, prove out, and qualify forming processes, including press brake forming, rolling and roll forming, hydroforming, spinning, and expanding or sizing.
Develop welding processes and weld schedules for TIG (GTAW), resistance spot, and resistance seam welding in accordance with aerospace and customer specifications.
Write manufacturing documentation for shop-floor use, including process sheets or routers, work instructions, setup sheets, and weld schedules.
Design or specify and oversee the build of forming tools, weld fixtures, assembly and drill fixtures, and inspection fixtures; work with the toolroom on tool build and tryout.
Collect and analyze process and inspection data, including SPC, CMM and inspection results, scrap, rework, and yield, and use it to justify and implement process changes that reduce variation and improve first-pass yield.
Lead root cause and corrective action investigations for nonconformances, from containment through root cause identification, permanent corrective action, and effectiveness verification.
Troubleshoot forming, welding, and assembly processes on the shop floor and document improvements that prevent recurrence.
Review customer drawings, specifications, and purchase order requirements; interpret GD&T; and create properly dimensioned and toleranced shop drawings and in-process sketches.
Support special process requirements, including welding, laser, heat treat, and NDT, in accordance with customer requirements.
Partner with Quality, Production, Programming, and the Toolroom; provide hands-on shop-floor support and operator training.
Drive continuous improvement using Lean manufacturing principles.