Methods Engineer

Position Summary

Magellan Aerospace has an exciting new opportunity for a Methods Engineer in New York. The purpose of this position is to design, implement, and optimize manufacturing processes to improve productivity, efficiency, and quality while managing product configurations and ensuring effective handling of customer data across the product lifecycle.

• Oversee the collection, organization, and storage of customer data related to products, including 2D and 3D technical documents and specifications, ensuring compliance with customer agreements and confidentiality agreements.
• Establish and manage product configurations and BOMs (Bill of Materials), ensuring that all product versions are accurately tracked, documented, and aligned with customer specifications.
• Maintain detailed records of process flows, configurations, work instructions, and customer data. Ensure all documentation is up-to-date and easily accessible for internal and external stakeholders.
• Lead or support change control processes, ensuring that any modifications to product design or manufacturing processes are carefully documented, reviewed, and approved.
• Develop, implement, and improve manufacturing methods and processes to enhance product quality, efficiency, and cost-effectiveness.
• create and maintain process documentation, including work instructions, process flow diagrams, and standard operating procedures (SOPs) to ensure consistency and clarity in operations.
• Analyze existing manufacturing workflows and identify opportunities for process improvements, reducing cycle times, eliminating waste, and increasing throughput.
• Evaluate and recommend new equipment, tools, and technologies to improve manufacturing capabilities and integrate them into existing processes.
• Work closely with production teams, engineers, quality assurance, and maintenance departments to resolve process-related issues and improve overall operations.
• Implement and support lean manufacturing principles such as 5S, Kaizen, value stream mapping, and continuous improvement initiatives to streamline processes and reduce waste.
• Lead or participate in root cause analysis for process failures or quality issues, and develop corrective actions to prevent recurrence.
• Provide training and technical support to operators and other manufacturing personnel on new processes, tools, and equipment.
• Identify and implement cost‑saving opportunities without compromising product quality or safety standards.
• Ensure that all processes meet quality standards and regulatory requirements, including industry‑specific certifications.
• Conduct process validation and testing to ensure processes meet required specifications and performance criteria.
• Monitor and track key performance indicators (KPIs) related to manufacturing processes, and provide regular reports to management regarding process performance and improvements.
• Ensure that all processes adhere to relevant industry standards, customer requirements, and regulatory compliance (e.g., ISO, AS9100, etc.).
• Perform regular audits of customer and configuration data to verify its accuracy and consistency across various systems (ERP, PLM, etc.).
• Provide guidance and training to internal teams on the management of customer data, product configurations, and related processes.

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related field.
• 3+ years of experience as a Methods Engineer, Manufacturing Engineer, Quality Engineer, or similar role in a manufacturing environment (preferably in aerospace, automotive, medical device, or industrial equipment industries).
• Experience with process improvement methodologies such as Lean, Six Sigma, or other continuous improvement tools is preferred.
• Strong experience in defining, analyzing and optimizing manufacturing workflows and processes.
• Strong knowledge of manufacturing processes, such as machining, grinding, assembly and finishing processes.
• Expertise in process mapping, workflow analysis, and process documentation.
• Proficiency in CAD software (CATIA, NX or similar).
• Experience with data analysis and statistical process control…