Lead Manufacturing Engineer

LEAD MANUFACTURING ENGINEER

Position Overview

Thrush Aircraft LLC is seeking a Lead Manufacturing Engineer to serve as a technical authority for our aircraft production lines. This role is responsible for evaluating complex aerospace manufacturing processes, creating precision-sequenced work instructions for airframe assemblies, and leading Continuous Improvement initiatives. You will implement mistake-proofing (poka-yoke) specifically for sheet metal fabrication, prioritize high-mix workflow, and oversee advanced tooling requirements.

As a Lead, you will ensure Thrush Aircraft delivers flight-critical products with maximum efficiency and uncompromising quality. You must possess deep expertise in aerospace tool design, sheet metal forming, and precision assembly methods, while exemplifying commitment to aerospace standards and proactive project management.

Reports To: Director of Engineering

Essential Job Functions:

Airframe Process Design: Interpret complex aerospace engineering drawings and GD&T to organize the production of sheet metal and welded assemblies and sub-assemblies into logical, standardized operations via the Manufacturing Execution System (MES).

Sheet Metal Subject Matter Expert: Provide technical solutions for precision bending, riveting, dimpling, and chemical sealing processes.

Configuration Management: Maintain and audit EBOM, MBOM, and ABOM aircraft configurations to ensure "as-built" matches "as-designed."

Producibility & Capability: Perform productibility studies on new and legacy designs, focusing on sheet metal spring-back, material grain orientation, and fastener edge distance requirements.

Advanced Tooling: Evaluate and oversee the design of new tooling, form blocks, and assembly jigs required for legacy and future aircraft models.

Continuous Improvement: Lead LEAN process control and waste reduction specifically targeting high-value aerospace alloys and long-lead components.

Root Cause & Corrective Action (RCCA): Perform technical Root Cause analysis on manufacturing defects, implementing robust Corrective Actions to minimize scrap and rework.

Material Review Board (MRB): Leads the MRB process to drive first time right quality initiatives.

Regulatory & Safety: Ensure all manufacturing procedures adhere to FAA-conformity standards, as well as EH&S and NADCAP-aligned process controls.

Mentorship: Train and guide production personnel and junior engineers in MES processes and advanced aerospace fabrication techniques.

Skills and Abilities:

Aerospace Mastery: Advanced knowledge of aircraft manufacturing processes, specifically sheet metal fabrication and structural assembly.

Tooling Design: Proven ability to design or specify jigs, fixtures, and templates for consistent aircraft component production.

Quality Focused: Deep familiarity with aerospace quality assurance techniques and First Article Inspection (FAI) per FAA quality standards.

Technical Proficiency: Expert-level use of CAD software (SolidWorks/CATIA) and MS Office.

Leadership: Strong project management skills with the ability to lead cross-functional teams through production bottlenecks.

Education and Experience:

Bachelor's Degree in Aerospace, Mechanical, or Manufacturing Engineering is mandatory.

7+ years of experience in a Manufacturing Engineering capacity, with a strong emphasis on aerospace sheet metal environments.

Specialized Knowledge: Proficiency in machining, automated fabrication, and the heat-treatment characteristics of aerospace aluminum alloys.

Flexibility: Ability to lead through critical production deadlines, including occasional late shifts or Saturdays.

Hands-on experience in aircraft manufacturing and assembly is a plus.