Propulsion Engineering Manager

Company Overview

Firecrest Aerospace is a U.S. aerospace propulsion company headquartered in Morrisville, North Carolina, with manufacturing operations being established in Stevens Point, Wisconsin. As a subsidiary of CSE USA, Inc., a member of CSG Group, Firecrest develops and manufactures advanced micro turbojet and turbofan engines for defense, aerospace, and other high-performance applications, supporting U.S. government, allied, and commercial customers.

The company is investing approximately $15 million to establish its initial U.S. manufacturing facility in Stevens Point, where it expects to create approximately 125 high-skilled manufacturing, engineering, and technical positions. As Firecrest expands from engine assembly, integration, and testing into full-scale manufacturing, engineering, and advanced product development, it is helping strengthen the U.S. aerospace and defense industrial base while advancing next-generation propulsion technologies.

At Firecrest Aerospace, you will have the opportunity to work alongside a growing team committed to engineering excellence, innovation, and mission success. Whether your expertise is in manufacturing, engineering, quality, operations, or business functions, you will play a direct role in building advanced propulsion systems that support critical national security and aerospace missions.

Position Summary

The Propulsion Engineering Manager is responsible for establishing and scaling engineering support for a small turbine engine assembly and test facility. This role begins as an individual contributor reporting to a remote VP of Operations, working in close coordination with the Operations Manager and Quality Manager to stand up the technical and process foundation of the site.

In Phase 1, the Engineering Manager will work in tight coordination with the Quality Manager and Operations Manager operate hands-on, resolving design-for-manufacturing gaps, stabilizing inherited product definitions, and supporting early builds.

As the organization transitions into production (Phases 2 and 3), the role evolves into a leadership position reporting to the on-site Plant Manager, leading a small team of manufacturing and propulsion engineers.

This role is central to enabling production scale from New Product Introduction (NPI) through full-rate production by systematically eliminating variability, resolving failure modes, and improving first pass yield prior to increasing throughput and takt time.

Organizational Scaling & Engineering Ownership

Phase 1: Site Startup & NPI (Individual Contributor reporting to VP of Propulsion Operations)

Stabilize Product & Process Definition

• Partner with Operations and Quality to co-develop foundational assembly and test processes
• Analyze and “wring out” variability from inherited technical data, including:
• Drawings and specifications from external/legacy sources
• Assembly procedures and work instructions
• Test procedures and acceptance criteria
• Identify gaps in tolerances, stack-ups, and unclear requirements impacting build consistency
• Establish initial variation management strategy, including:
• Critical-to-quality (CTQ) identification
• Early tolerance analysis and risk assessment
• Support early engine builds, troubleshooting issues in:
• Assembly processes
• In-process testing
• Rotor balancing and mechanical integrity
• Final acceptance test anomalies
• Begin development of fault trees for known and emerging failure modes
• Participate in and help facilitate:
• Design FMEAs (DFMEA) with design authority
• Process FMEAs (PFMEA) with Operations
• Support structured problem-solving using 8D Problem Solving when appropriate
• Support Operations’ technician training on assembly/test intent, procedures, and known failure modes

Phase 2: NPI → Low-Rate Initial Production (LRIP) (Functional Manager reporting to Plant Manager)

Improve First Pass Yield (FPY)

• Hire and lead:
• One Manufacturing Engineer
• One Propulsion Engineer
• Mature and deploy variation management processes established in Phase 1:
• Refine tolerances and reduce ambiguity in drawings and specs
• Standardize and validate assembly and test procedures
• Align engineering outputs with quality control plans and inspection methods
• Lead technical troubleshooting to eliminate repeat failure modes across:
• Assembly defects
• In-process test failures
• Balancing issues
• Final acceptance test failures
• Expand and formalize fault tree analysis as a standard diagnostic tool
• Drive FPY improvement through:
• Root cause identification and elimination
• Close linkage with PFMEA and control plans
• Structured RCCA using 8D Problem Solving where warranted
• Train and certify technicians on:
• Updated assembly and test procedures
• Failure mode recognition and escalation paths
• Collaborate closely with:
• Operations to stabilize workflows and reduce variability
• Quality to ensure alignment between engineering intent, inspection, and acceptance criteria

Phase 3: LRIP → Full-Rate Production (FRP) (Functional Manager reporting to Plant Manager)

Enable Throughput & Takt Time Improvement (After FPY Stabilization)

• Hire and lead:
• Second Manufacturing Engineer
• Second Propulsion Engineer
• Transition focus from defect reduction to process capability and throughput optimization
• Further reduce variation to enable predictable, repeatable cycle times
• Support operations in line balancing and bottleneck reduction through:
• Process improvements
• Tooling and fixture optimization
• Test system efficiency improvements
• Enhance fault tree models using production data for faster troubleshooting
• Ensure engineering documentation is fully controlled, stable, and production-ready
• Continue training and upskilling workforce as processes evolve
• Partner with Quality to ensure FMEAs and control plans reflect real production conditions
• Support scaling of test infrastructure and performance consistency

Key Responsibilities (Across All Phases)

• Own engineering support for assembly and test operations
• Lead troubleshooting of technical issues across the production lifecycle
• Develop and maintain fault trees for critical failure modes
• Drive variation reduction in product definition and manufacturing processes
• Participate in DFMEA and PFMEA development and maintenance
• Lead and support structured problem solving and RCCA efforts
• Train technicians on procedures, failure modes, and engineering intent
• Develop and lead the engineering team
• Collaborate cross-functionally with Operations and Quality

Qualifications

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field

7+ years of experience in propulsion systems, aerospace manufacturing, turbine engine assembly, balancing, and test

Experience with legacy product transfer or inherited designs

Demonstrated experience transitioning products from NPI to production with a background in startup manufacturing

Strong troubleshooting skills in mechanical systems, assembly, and testing

Experience with tolerance analysis and variation reduction

Familiarity with FMEA and structured problem-solving methodologies

Familiarity with 8D Problem Solving and RCCA processes

Six Sigma or equivalent analytical training

Key Competencies

• Strong systems thinking and root cause analysis capability
• Ability to translate design intent into robust production processes
• Hands-on, solution-oriented mindset
• Cross-functional collaboration and influence
• Ability to scale engineering support alongside production growth

Work Environment

• On-site role within a turbine engine assembly and test facility
• Significant time spent on the production floor and in test environments
• Exposure to mechanical systems, rotating equipment, and test operations

Why This Role Matters

This role ensures that engineering rigor translates into production reality. By eliminating variability, resolving failure modes, and enabling stable, repeatable processes, the Engineering Manager is a key driver of first pass yield, throughput, and overall production success as the facility scales from initial builds to full-rate manufacturing.

What We Offer

• Competitive base salary with performance-based incentives.
• Comprehensive benefits package, including medical, dental, and vision insurance.
• 401(k) retirement plan with company contribution.
• Paid time off including vacation, personal days, and company holidays.
• Professional development and training opportunities.
• Entrepreneurial, collaborative, and mission-driven work environment