Senior Staff Mechanical Engineer - Aerospace Gearing

Woodward is committed to creating a great workplace for all team members. Our company and its members are committed to acting with integrity, being respectful and accountable to one another, and staying humble and driven, while maintaining the highest professional and ethical standards.We are steadfastly committed to attracting the best talent across our communities creating a rewarding workplace. Together we are fulfilling our purpose to design and deliver energy control solutions our partners count on to power a clean future.Woodward supports our members’ wellbeing and regularly benchmarks with other companies in our industry to offer an extensive Total Reward package for this position. Salary will be determined by the applicant's education, experience, knowledge, skills, and abilities, as well as internal equity and alignment with market data.Estimated hourly base pay: $145,000 (Minimum) - $181,000 (Midpoint) - $218,000 (Maximum)All members included in annual cash bonus opportunity.401(k) match (4.5%)Annual Woodward stock contribution (5%)Tuition reimbursement and Training/Professional Development opportunities for all members12 paid holidaysIndustry leading medical, dental, and vision Insurance upon date of hireVacation / Sick Time / Vacation Buy-up / Short Term Disability / Bereavement leave.Paid parental leave.Adoption AssistanceEmployee Assistance Program, including mental health benefits.Member Life & AD&D / Long Term Disability / Member Optional LifeMember referral bonusSpouse / Child Optional Life / Optional AD&D / Healthcare and Dependent Care Flexible SpendingVoluntary benefits, including:Home / Auto Insurance discountsWhole Life Insurance / Critical Illness Insurance / Legal Assistance / Military LeaveKey Responsibilities:Advanced Gear Process Development & IndustrializationLead end-to-end development of aerospace-qualified gear manufacturing processes development including spur, helical, bevel, and spline gears.Define and document:Process flows, PFMEAs, control plans, and work instructionsKey Characteristics (KCs) and Critical-to-Quality (CTQ) featuresProcess capability requirements (Cp/Cpk) for critical gear geometryWork cooperatively with gearing designs to improve performance & manufacturability of new gearing productsDevelop and optimize machining processes including:Hobbing, shaping, skiving, broachingProfile and generating grindingHoning, lapping, and superfinishingEstablish robust process control strategies for:Tooth profile accuracy, pitch variation, lead/helix errorSurface finish, residual stress, and distortion controlDefine machining parameters, tooling strategies, and thermal controls to ensure repeatability in ultra-tight tolerance aerospace components.Lead process validation (IQ/OQ/PQ) and AS9102 First Article Inspection (FAI).Drive continuous improvement:Reduction of transmission error and gear noiseImproved process capability and yieldImplementation of advanced machining techniques and in-process monitoringSupplier Development & Special Process ManagementServe as technical authority for gear manufacturing suppliers and special process providers.Lead supplier qualification and audit activities to ensure compliance with:AS9100 quality systemsAerospace customer requirementsInternal engineering specificationsOversee and manage NADCAP-controlled special processes, including:Heat treatment (carburizing, nitriding, induction hardening)Shot peening and residual stress controlSurface treatments (coatings, plating, corrosion protection)Non-destructive testing (MPI, FPI, ultrasonic)Ensure detailed and accurate technical requirement flow-down, including:Gear macro- and microgeometry specificationsSurface integrity and metallurgical requirementsFull traceability and certification needsPartner with suppliers on:Process capability improvement initiativesRoot cause corrective action (RCCA, 8D)Monitor supplier performance via KPIs and support make vs. buy decisions.Quality Engineering & Inspection (Precision Components)Define and implement advanced inspection strategies for aerospace precision components, with emphasis on gearing.Establish and validate measurement systems (MSA, Gage R&R) for:Gear profile, lead, pitch, runout, and composite errorSurface finish, waviness, and microgeometryUtilize analytical inspection equipment (e.g., Klingelnberg, Gleason, Zeiss).Ensure compliance with:AGMA, ISO, DIN, and aerospace standardsCustomer and regulatory requirementsLead and support:AS9102 First Article Inspection (FAI)Internal, customer, and regulatory auditsDrive structured root cause investigations addressing:Transmission error and NVH performance issuesContact pattern deviations and load distributionSurface distress, wear, and fatigueImplement SPC and continuous monitoring of critical characteristics.Ensure full traceability, documentation, and configuration control for flight hardware.Manufacturing & Technical LeadershipProvide hands-on support to resolve complex machining and finishing issues on the shop floor.Collaborate with design engineering on:Manufacturability (DFM)Tolerance stack-up and performance requirementsMentor engineers and technicians in aerospace manufacturing best practices.Interface cross-functionally with Design, Quality, Supply Chain, and Program Management.Key Skills:Effective written and verbal communication skills including presentations, (Customer, internal and management). Writes and communicates critical reports. Leads complex design reviews, internally and Customer. Expert technical writing skills (procedures, reports, etc.)Competent complex problem solving/troubleshooting skills for both components and subsystems.Promotes a cross-functional project team environment, communicates with Customers and leads small teams. May participate in setting technical direction/product strategies. Provides technical problems-solving guidance to others.Strong expertise in:Gear cutting and finishing processesGear metrology and inspectionGD&T and precision tolerancingExperience with:AS9100 quality systemsAS9102 FAI requirementsCNC and gear manufacturing equipmentNADCAP special processes and supplier auditsFamiliarity with aerospace OEM requirements (Boeing, Airbus, etc.)Lean Six Sigma certificationAdvanced knowledge of gear analysis and inspection systemsBackground in tribology and gear system performanceOther Qualifications:Bachelor’s degree in a relevant field and 12+ years of applicable experienceCertified Technician or equivalent technical certificationExperience with precision ball screw manufacturing is preferred and adds value for aerospace actuation systems. Familiarity with the following would be great to have:Thread grinding, thread rolling, and whirling processesHeat treatment and distortion control of long, slender componentsPrecision assembly, preload setting, and end-of-line functional testingLead accuracy, positioning error, backlash control, and preload optimizationFriction, efficiency, and wear characteristics in high-load applicationsLead measurement, travel variation analysis, preload verification, and torque-to-rotate testingPrecision measurement techniques similar to gearingThis position requires use of information which is subject to the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). All applicants must be U.S. Persons within the meaning of the ITAR and EAR, or eligible to obtain all required authorizations from the U.S. Department of State and/or the U.S. Department of Commerce. The ITAR defines a U.S. Person as a U.S. citizen or national, lawful permanent resident (i.e., 'Green Card holder'), or a protected person (e.g., asylee, or refugee).Woodward is an equal opportunity employer and does not discriminate in hiring or employment on the basis of race, color, religion, sex (including sexual orientation and gender identity), national origin, age, disability, protected veteran status, or any other category protected under federal, state, or local laws.#LI-AT1 #J-18808-Ljbffr MPC Products Corporation (Woodward MPC, Inc.)