Senior Maintainability Engineer in Manassas

Job Description Job Description

At Electra, we're pioneering sustainable aviation by developing hybrid‑electric Ultra Short Takeoff and Landing aircraft designed to transform regional air mobility, by making air travel more efficient, quieter, and environmentally friendly. Able to operate from soccer field‑sized spaces, our Ultra Short unlocks a new era of aviation through what we call Direct Aviation - the next level of connectivity bringing air travel closer to where we live, work, and play.

Headquartered in Northern Virginia, with additional locations in Switzerland, we're building a diverse team of global professionals passionate about redefining the future of aviation.

The Senior Maintainability Engineer will play a key role in the design and development of the aircraft and its installed systems. As this is a Ultra Short Aircraft program, the position requires innovative approaches to reliability and maintainability to support the integration of both electric and conventional propulsion technologies.

This is a broad and senior technical role, encompassing design support, analysis, and compliance demonstration. The Senior R&M Engineer will provide specialized support to multidisciplinary engineering teams-including systems, structures, and customer support-to ensure that reliability, availability, and maintainability objectives are achieved up to and beyond Entry Into Service (EIS).

R&M strategies - Establish and maintain Reliability and Maintainability processes aligned with program objectives and applicable industry standards.

Schedule Reliability and Availability targets - Define, track, and report aircraft reliability and availability metrics to achieve performance goals for Entry Into Service (EIS) and beyond.

Perform R&M analyses - Conduct and manage FMEA/FMECA, Fault Tree Analysis (FTA), and Maintenance Task Analysis (MTA) to evaluate system reliability and maintenance characteristics.

R&M documentation - Prepare and update R&M Plans, Procedures, and Reports in accordance with ARP
4754A and MSG-3 methodologies.

Define on-board maintenance capabilities - Lead the definition and validation of built-in test (BIT), fault detection, and fault isolation logic to enhance troubleshooting efficiency.

Maintenance documentation - Support the creation of the Fault Isolation Manual (FIM) and related maintenance documentation such as AMM, CMM, and SRM.

Aircraft Connectivity initiatives - Collaborate in the design of connectivity and data‑management features that enable predictive maintenance and digital troubleshooting.

Ground Operations and Customer Support - Ensure maintainability requirements are incorporated into aircraft design, support tools, and operational procedures.

Coordinate R&M reviews and deliverables - Promote design reviews, validate assumptions, and support integration of R&M data into the Maintenance Planning Document (MPD) and Maintenance Review Board Report (MR ).

Recommend design improvements - Analyze reliability data and maintenance findings to propose design changes that improve aircraft availability and reduce lifecycle costs

Drive the Lessons Learned process - Capture and analyze in‑service data to identify improvement opportunities and feed them back into future aircraft configurations.

• Bachelor's degree in engineering and 12+ years of experience in aerospace maintenance, support, or contract management (or an equivalent combination of education, skills, and experience).
• Industry
  
  Experience:
  
  
  • Experience with an advanced air mobility startup (e.g., Volocopter, Lilium) and an established aircraft OEM (e.g., Embraer, Airbus, Boeing) .
• Maintenance & Support Expertise:
  • Experience in Reliability and Maintainability Engineering within the aerospace industry.
  • Strong understanding of aircraft maintenance programs, service‑level agreements (SLAs), and vendor negotiations.
  • Experience defining and tracking Schedule Reliability and Availability KPIs for aircraft programs.
  • Knowledge of maintenance processes, ground operations, and in‑service engineering support.
  • Exp…