Composite Manufacturing Engineer

Job Description Summary

At Dowty (a GE Aerospace company) we design, manufacture, repair and overhaul a range of propeller systems for Military and Civil applications. This is done from our new state of the art facility in Gloucestershire, UK.

In this role you will be part of the new product introduction (NPI) team to provide support to the growing demand for new propeller manufacturing systems and contribute to develop the next generation of electrified, sustainable aviation. You will be a highly valued member of the Manufacturing Engineering department who are empowered across GE Aerospace to ensure design intent is correctly translated using our production system.

You will ensure design for manufacturing remains a key focus during the development cycle of our products. Through development and pilot production you will provide feedback to the design team, aid the design team in resolving issues, supply documentation, tooling and training to allow the product to be built in a clean manufacturing environment.

With a focus on manufacturability, you will help contribute to the development of new composite processes mostly, facilities and capabilities and assist with the adoption of automation and new technologies to ensure repeatability and reliability in the manufacturing process.

Responsibilities

• A hands‑on approach to working directly with the manufacturing and engineering teams to help resolve manufacturing engineering issues using data, rationale and logic.
• Influencing design engineering to ensure manufacturing is represented during the product development process and design for manufacture/assembly is a priority consideration for the duration of the programme.
• Developing test routines to establish process parameters around new technologies and systems to guide manufacturing application and determine feasibility of designed solutions.
• Employ a variety of virtual manufacturing tools to simulate workflow, automation sequences and space requirements to inform capacity plans, resource requirements and line balancing.
• Develop robust, lean solutions for equipment layouts, process design and product flow to maximise ROI and reduce hours/costs per unit.
• Working to ensure that process capability, cycle time and equipment availability targets are achievable through application of automation/existing solutions as well as new technology introduction.
• Define equipment lists, spare requirements, training requirements (production, ME and maintenance), work instructions and substance/equipment safety documentation.
• Be a key part of an APQP rollout and an FMEA critical characteristic cascade into internal & supplier quality operating systems.
• Lead the installation/commissioning process to deliver a system through continuous improvement & root cause analysis that meets delivery targets and operations requirements across safety, quality, delivery & cost (SQDC).

Qualifications/Requirements

• Bachelor’s degree or above in Engineering with considerable experience or equivalent knowledge and experience in Technical Project / Program Management.
• Experience or knowledge of the New Product Introduction (NPI) process within manufacturing and elements of project planning.
• Essential - manufacturing background with previous experience in facilities development and engineering including robotics, automation & conveyor technologies.
• Demonstrated ability to optimise existing processes for throughput, quality and availability at both the design and commissioning phases.
• Knowledge of problem solving methodologies (Lean, Six Sigma, 8D, PPS, RedX) and APQP requirements.
• Experience defining FMEAs cascading of critical characteristics into a control plan and subsequent development of a manufacturing quality operating system.
• Experience working with subcontracted suppliers and vendors.
• Knowledge of health & safety (H&S) and construction design & management (CDM) regulations and means of compliance.

Desired skills

• Experience with high volume composite (CFRP/RTM) and/or high tolerance machined parts manufacturing.
• Experience with 3D Catia, 2D AutoCAD and/or another CAD package
• Experience in working within a highly regulated industry…