Composite Manufacturing Engineer

General Atomics Aeronautical Systems, Inc. (GA-ASI), an affiliate of General Atomics, is a world leader in proven, reliable remotely piloted aircraft and tactical reconnaissance radars, as well as advanced high-resolution surveillance systems.

We have an exciting opportunity for an Experienced Composites Manufacturing Engineer in our GA-ASI/Aircraft Systems Group.

Much of GA-ASI Composites Manufacturing Engineering roles/responsibilities are centered on projects. Projects range from program/platform leadership/support, maturing manufacturing/materials/processes, continuous improvement, capital acquisition, and facility improvements/expansion. Projects originate from a data-based articulation of need within Composites Manufacturing.

As an Experienced Composite Manufacturing Engineer your role will be to lead and support - through rigorous quantitative analysis - multiple projects within GA-ASI's product/platform line suite (Improved Grey Eagle, Certified Pred B, special projects, etc.), and within our range of manufacturing operations (material cutting/kitting, lamination, cure, demold, trim/drill/machining, and assembly). This includes leading/supporting top-tier teams of Manufacturing Engineers and technicians and developing manufacturing technology while ensuring aerospace standards and quality requirements are met.

This position required depth and breadth of aerospace composite manufacturing, processing and materials knowledge. Project engineering and management experience is required. Must be able to multitask multiple and complex projects while staying organized in a fast-paced environment. Must be able to collaborate, negotiate, and work with internal and external groups to ensure ideas come to fruition.

DUTIES AND RESPONSIBILITIES:

• Must have experience with CNC Machining, Composite Lamination Operations, and / or Composite Structural Assembly.
• Composite Lamination specific;
  • Familiar with laser projector systems
  • Hands-on experience with Fibersim
  • Design, build, and maintain lamination mold tooling
  • Knowledge of ATL and/or AFP
• CNC Machining specific;
  • Improve CNC machining process to achieve Cpk goal and OEE goal
  • Familiar with SMED (single minute exchange of die)
  • Experience with MasterCam and Vericut
  • Develop, review, and maintain mill fixtures
• Composites, Structural Assembly specific;
  • Familiar with Tooling concepts to reduce variability.
  • Experience with Bonding and Fastening of aerostructures.
  • Competent in completing tolerance stack studies of complex assemblies for Root Cause Corrective Actions.
  • Experience developing new and improve existing Assembly and Finish processes to reduce cost and improve Quality.
• Devise new approaches to resolve unusual or highly complex manufacturing problems through early, upfront design-for-manufacturing (DFM) principles to ensure producibility, inspectability, testability, maintainability and repairability.
• Troubleshoot conflicting design development vs. production requirements, promotes new methods / process equipment, and evaluates special material requirements.
• Define and implement new manufacturing technologies.
• Provides input to design, technical staff, briefs management, and participates effectively in a team of experienced professional staff.
• Must have an extensive working knowledge of advanced composites production operations
• Develop composite manufacturing processes, procedures and tooling using technical experience and collaborative interaction with the team to improve quality, eliminate non-value-added steps and shorten lead times.
• Initiate and implement Lean and Six Sigma Projects to improve quality, lower costs, and remove tribal knowledge.
• Establish process/specification control limits while seeking out opportunities for Poka Yoke.
• Oversee prototype and pilot builds, document the build process with standardized work instructions, develop shop aids and routers
• Lead PFMEAs
• Responsible for observing all laws, regulations and other applicable obligations wherever and whenever business is conducted on behalf of the Company.
• Expected to work in a safe manner in accordance with established operating procedures and practices.

We recognize and appreciate the value and contributions of individuals with diverse backgrounds and experiences and welcome all qualified individuals to apply.

Job Qualifications:

• Typically requires a bachelors degree, masters degree or PhD in engineering or a related technical discipline from an accredited institution and progressive engineering experience as follows; four or more years of experience with a bachelors degree or two or more years of experience with a masters degree. May substitute equivalent engineering experience in lieu of education.
• Demonstrates a detailed and extensive technical expertise and application of engineering principles, concepts, theory, and practice with the ability to organize, plan, schedule, conduct, and coordinate workloads to meet established deadlines or milestones with some experience in project leadership.
• Must possess the ability to understand new concepts quickly and apply them accurately throughout an evolving environment; strong communication, presentation, and interpersonal skills to effectively interface with other departments, customers, government representatives, and/or professionals; the capability of representing the organization as a prime technical contact; and, the ability to provide leadership and guidance to less experienced professionals.
• Must be customer focused and able to work on a self- initiated basis or in a team environment.

Salary:$73,650 - $128,663

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