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 processes 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 engineer turns customer prints into stable, documented, repeatable manufacturing processes and provides hands-on support on the shop floor. The position works with Quality, Production, Programming, and the Toolroom, and supports operators through training and troubleshooting. It also supports special process requirements, including welding, laser processing, heat treat, and NDT, in accordance with customer requirements.

Requirements

At least 10 years of experience as a manufacturing, process, or fabrication engineer in aerospace or a similar precision sheet metal environment.
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.
Experience with flat-pattern and blank development, bend allowance, springback, and forming limits.
Experience with press brake forming, rolling, and hydroforming.
Strong working knowledge of welding processes and weld fixturing, including TIG (GTAW), resistance spot, and resistance seam welding.
Knowledge of 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 make process changes.
Knowledge of metal types and their forming and welding characteristics, 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.
Possible travel as required for training.

Nice To Haves

Jet engine component experience.
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, including G and M code and NX CAM, and/or laser programming experience.
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 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 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, to justify and implement process changes, 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 shop drawings and in-process sketches with appropriate dimensioning and tolerancing.
Support special process requirements for welding, laser processing, 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.