JOB SUMMARY

The Senior Manufacturing Engineer for Alloy Surfaces Company (ASC) establishes, monitors, and improves processes related to the manufacture of complex commercial, defense, and aerospace products and systems. This position operates with minimal supervision and provides technical leadership for manufacturing process development, tooling and equipment, production readiness, and continuous improvement. The Senior Manufacturing Engineer develops and maintains manufacturing processes that produce products at the lowest practical cost, at quality levels exceeding customer expectations, and on or ahead of schedule.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Lead the evaluation, development, qualification, and implementation of new technologies, processes, equipment, tooling, and fixtures, and share lessons learned and best practices
• Perform and facilitate ergonomic assessments, Process Hazard Analyses (PHA), and Job Hazard Analyses (JHA) to ensure manufacturing processes incorporate appropriate safety controls
• Develop manufacturing documentation including instructions, routers, bills of material, assembly procedures, build sequences, and rework/repair instructions
• Collaborate with Engineering, suppliers, and subject matter experts during product design and reviews to provide DFM, producibility, materials, tooling, and manufacturing process recommendations
• Troubleshoot manufacturing and product quality issues using root cause and failure analysis; lead corrective actions and provide technical support to resolve significant or line-down issues
• Support the disposition of non-conforming material and develop rework, repair, and corrective action requirements for internal and supplier-related issues
• Lead and participate in continuous improvement initiatives using Lean, Six Sigma, Kaizen, 5S, Kanban, QCO, and other methods to improve efficiency, quality, cost, and process capability
• Lead assigned manufacturing engineering and CapEx projects including project planning, scheduling, budgeting, resource management, design oversight, and vendor coordination
• Collaborate with management, Engineering, Production, Quality, customers, suppliers, and other stakeholders to communicate technical issues, manufacturing strategies, root cause findings, and performance metrics
• Assist in the development of transition to production plan(s) and determine full-rate tooling and equipment needs
• Provide input to activities such as supplier evaluation, source selection, request for proposal submittal reviews, best value determination, and supplier capacity analysis
• Attend activities including Supplier Production Readiness Evaluation (SPRE) and Manufacturing Product Process Verification (MPPV) events
• Provide technical expertise in analyzing and improving supplier manufacturing capabilities, capacity, manufacturing, test, failure analysis, and part selection
• Review drawing changes and contract modifications to determine impact to the manufacturing process and incorporate the required changes
• Contribute to new business proposal activity in cost estimating and developing manufacturing strategy
• Define and improve the product value stream and process capabilities for different types of manufacturing processes and equipment
• Apply knowledge of product design, materials, and production processes to define assembly procedures and build sequences to drive operational efficiency
• Define materials, tooling, fixtures, and manufacturing methods to ensure safety and quality are incorporated into the process design
• Influence the development of manufacturing strategy for the area of responsibility including work cell layouts, equipment, tooling, and processes/systems

OTHER JOB FUNCTIONS

• Ensure compliance with all company policies and procedures, including but not limited to the Code of Conduct, U.S. Code of Ethics and Business Conduct, and the Chemring Operational Framework
• Ensure the Group ethos of all employees going home safely at the end of their working day is adhered to
• Promote a high standard of ethical behavior and adherence to the Group’s core values, and promote a culture of honesty and integrity across ASC
• Comply with government and corporate laws, rules, regulations, policies, and procedures
• Special projects and additional duties as assigned

SUPERVISORY RESPONSIBILITY

• N/A

EDUCATION/CERTIFICATION

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Materials Science, Manufacturing Engineering or related field
• Lean Six Sigma Green Belt certification preferred
• Experience in Design for Manufacturability Analysis preferred

EXPERIENCE

• Minimum of six years of experience in a regulated manufacturing environment, preferably aerospace or defense
• Experience in the application of Design for Manufacturing and Assembly (DFMA) and Design for Cost (DFC) principles

ADDITIONAL SKILLS AND QUALIFICATIONS

• Must be eligible to obtain and/or maintain a U.S. Government Security Clearance commensurate with the level of facility clearance
• Strong interpersonal, communication, influencing, and organizational skills with the ability to collaborate effectively across all levels of the organization
• Excellent problem-solving skills with the ability to apply sound judgment, initiative, and creativity to complex technical challenges
• Strong capabilities and experience supporting manufacturing production lines, e.g., resolving line-down events, troubleshooting, and creating standard operating procedures and work instructions
• Ability to develop reports, business correspondence, technical documentation, and quality procedures
• Ability to manage competing priorities in a fast-paced manufacturing environment
• Statistical Analysis and Statistical Process Control
• Fault proofing, Root Cause Analysis
• Process Mapping /Value Stream Mapping
• Understanding of AS9100 and/or ISO 9001, and Lean Six Sigma Techniques
• Manufacturing process development and planning, test plan development
• Control and disposition of non-conforming material
• Working knowledge of CAD (Creo, SolidWorks, etc.) and Manufacturing ERP systems
• Proficiency with Microsoft Office Suite

PHYSICAL AND OTHER REQUIREMENTS

Lifting, carrying, pushing, pulling, or otherwise moving objects, weighing up to 20 pounds occasionally and/or a negligible amount of weight frequently. Involves sitting most of the time, but may involve walking or standing for brief periods of time. Use of computer.

DISCLAIMER

The preceding job description has been designed to indicate the general nature and essential job functions of this position. It is not designed to contain or be interpreted as a comprehensive inventory of all duties, responsibilities, and qualifications required of employees assigned to this job. Employees will be expected to perform other job functions and duties as may be needed and/or required.

EQUAL OPPORTUNITY EMPLOYER

Alloy Surfaces Company (ASC) is an equal opportunity employer. We evaluate applicants without regard to race, color, religion, sex, age, national origin, disability, veteran status, genetic information and other legally protected characteristics.

The “Know Your Rights” Poster is available here: EEO Know Your Rights 

ASC EEO Policy Statement is available here: EEO Policy Statement 

ASC is committed to working with and providing reasonable accommodations to individuals with disabilities. If you need a reasonable accommodation because of a disability for any part of the employment process, please send an e-mail to hr@alloysurfaces.com or call (703) 574-6049 and let us know the nature of your request and your contact information.