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Key Responsibilities and Required Skills for Jet Assembler

💰 $45,000 - $80,000

Aerospace ManufacturingAssemblyAviationFabrication

🎯 Role Definition

A Jet Assembler is a skilled aerospace manufacturing technician responsible for assembling, fitting, fastening, sealing, and testing aircraft structural components and systems (fuselage, wings, empennage, nacelles, control surfaces). The role requires precise interpretation of engineering drawings and work instructions, expert use of hand and power tools, adherence to quality and safety standards (AS9100, FAA/EASA regulations), and coordination with engineering, quality, and production planning teams to deliver conforming, airworthy assemblies on schedule.

Key SEO phrases: jet assembler, aircraft assembler, aerospace assembly technician, airframe assembly, composite layup, metallic structures, AS9100, FAA-compliant assembly.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Production Assembler or General Assembler in aerospace or manufacturing
  • Sheet Metal Fabricator or Composite Technician
  • Aircraft Maintenance Helper / Apprentice

Advancement To:

  • Senior Jet Assembler / Lead Assembler
  • Assembly Team Lead or Shift Lead
  • Manufacturing Supervisor or Production Manager
  • Quality Inspector / NDT Technician / Process Engineer

Lateral Moves:

  • Quality Assurance Inspector (airframe)
  • Composite Repair Technician
  • Wire Harness / Avionics Harness Assembler

Core Responsibilities

Primary Functions

  • Read, interpret and apply engineering drawings, wiring diagrams, blueprints, and 3D models to lay out, fit and assemble aircraft structural components (fuselage sections, wing skins, ribs, bulkheads) maintaining strict dimensional tolerances and alignment.
  • Perform precision drilling, countersinking, reaming, and fastener installation on metallic and composite structures using pneumatic and electric drills, CNC drill fixtures, torque wrenches, rivet guns (solid, blind, and Huck), and fastening tools, ensuring correct fastener type, size, and torque per engineering specifications.
  • Execute composite layup preparation, bonding, and curing support tasks including surface preparation, adhesive application, adhesive cure monitoring, and clamp/jig setup to produce high-integrity bonded joints and composite assemblies meeting layup and cure parameters.
  • Fit, trim, and join sheet metal and composite parts using hand tools, shears, brakes, and forming equipment; perform shimming, edge preps and final fitting to maintain aerodynamic profiles and structural load paths.
  • Install mechanical systems and subassemblies—actuators, linkages, brackets, fasteners—and interface hardware, ensuring correct clearances and function in accordance with installation drawings and torque specifications.
  • Assemble and route control cables, hydraulic lines, fuel lines and electrical harnesses where required, using crimping tools, soldering, wire looms and cable clamps while following wire routing, identification, and strain-relief requirements.
  • Perform detailed in-process visual inspections and dimensional checks with calipers, micrometers, height gauges and templates; record inspection results, non-conformances, and measurement data per inspection plans and work instructions.
  • Prepare, complete, and maintain serialized manufacturing documentation: traveler cards, production build logs, inspection records, first article inspection (FAI) packets, and material traceability to ensure full compliance with quality management systems (AS9100 / ISO 9001).
  • Follow and enforce safety procedures for hazardous materials, adhesives, sealants and solvent use per SDS; maintain clean work areas, use proper PPE, and practice 5S and lean manufacturing standards to reduce risk and defects.
  • Execute rigging and alignment checks on assembled airframe components using jigs, fixtures and laser/alignment tools; make final adjustments and measurements to meet engineering datum and straightness criteria.
  • Support functional testing of installed systems (mechanical travel checks, actuator runs, hydraulic pressure checks, latch operation) and document results; identify and report any system anomalies to engineering or quality.
  • Interpret and implement engineering change orders (ECOs), service bulletins, and build specification updates; revise assembly steps, update build documentation and communicate changes to the production team.
  • Diagnose assembly issues and implement corrective actions in collaboration with manufacturing engineering and quality; participate in root cause analysis and apply permanent fixes to recurring assembly defects.
  • Prepare parts and assemblies for non-destructive inspection (NDT) and coordinate with NDT technicians for dye-penetrant, eddy current or ultrasonic testing; address findings and complete corrective repairs to meet acceptance criteria.
  • Use manufacturing execution systems (MES), ERP and electronic work instructions to log time, update work orders, capture serial numbers, and track production status in real time.
  • Calibrate, inspect and maintain hand tools, torque wrenches, rivet guns and gauges; tag out or remove out-of-tolerance tools and work with tool room to ensure calibration compliance.
  • Train, mentor and provide on-the-job guidance to junior assemblers, apprentices and temporary staff; document training completion and maintain competency records for required tasks.
  • Operate material handling equipment (forklift, hoist) safely to move large subassemblies and components to and from workstations; ensure proper support and protection of sensitive surfaces during handling.
  • Participate actively in continuous improvement initiatives including Kaizen events, value stream mapping and defect reduction projects to increase throughput, reduce rework and improve assembly ergonomics.
  • Maintain scheduled production rates while meeting quality standards and work with planning to escalate material shortages, tooling issues or design ambiguities that could impact delivery timelines.
  • Apply corrosion prevention, sealant application and protective coating techniques for mating surfaces and fastener areas; follow cure and processing windows to maintain long-term structural integrity.
  • Ensure traceability and disposition of nonconforming parts; raise NCRs (Nonconformance Reports) and work with quality to generate containment actions and corrective action plans.
  • Adhere to regulatory requirements and company procedures for airworthiness, record retention and audit readiness; support internal and external audits by providing build records and demonstrating process compliance.

Secondary Functions

  • Assist in kitting and pre-assembly of components, verifying part numbers, quantities and shelf-life to ensure builds start with correct material.
  • Support shop-floor data collection efforts, including cycle time monitoring and defect logging to improve manufacturing KPIs and provide inputs for production planning.
  • Collaborate with engineering on manufacturability feedback and participate in design for assembly (DFA) reviews to reduce assembly complexity and costs.
  • Provide input to tooling and fixture design by documenting fitment challenges and proposing ergonomic improvements to assembly workstations.
  • Participate in cross-functional change control meetings, helping prioritize assembly-impacting engineering changes and communicating implications to technicians.
  • Perform light maintenance and housekeeping on assembly jigs, fixtures and workstations to preserve tooling accuracy and production readiness.

Required Skills & Competencies

Hard Skills (Technical)

  • Expert blueprint and engineering drawing interpretation, including GD&T and tolerance stack-up awareness.
  • Proven experience with mechanical fastening methods: solid rivets, blind rivets, Huck bolts, structural bolts and washers, and NAS/MS fastener standards.
  • Proficient in precision measurement tools: digital calipers, micrometers, height gauges, bore gauges, protractors and laser alignment tools.
  • Skilled in drilling, countersinking, reaming, riveting, and torque application with pneumatic and electric tooling; knowledge of fastener installation procedures.
  • Practical experience with composite work: layup prep, adhesive bonding, cure cycles, and post-cure handling or bonding of composite-to-metal joints.
  • Familiarity with AS9100/ISO 9001 processes, FAA or EASA regulatory requirements, and traceability/document control practices.
  • Competent with hand and power tools, rivet guns, torque wrenches, pneumatic drills, and CNC drill fixtures; familiarity with tool calibration procedures.
  • Basic electrical harness routing and crimping skills; ability to follow wiring diagrams and use crimping tools and cable identification methods.
  • Experience using MES/ERP systems and reading electronic work instructions, capturing serial numbers and maintaining production records.
  • Knowledge of basic NDT prep procedures and ability to interact with NDT technicians; understanding of acceptance criteria and repair disposition.
  • Familiarity with lean manufacturing, 5S, Kaizen and continuous improvement tools to reduce waste and improve assembly flow.
  • Safe operation of forklifts, hoists and material handling equipment; understanding of proper lifting and material support techniques for large assemblies.
  • Ability to read and execute engineering change orders, update build instructions and maintain up-to-date BOM references.

Soft Skills

  • Strong attention to detail and a commitment to producing defect-free assemblies.
  • Clear verbal and written communication skills for interacting with engineers, quality and production planners.
  • Collaborative team player who can work across disciplines and mentor less experienced technicians.
  • Problem-solving mindset with ability to identify root causes and implement practical fixes on the shop floor.
  • Time management and prioritization to meet production schedules while ensuring quality and safety.
  • Adaptability to changing production requirements, engineering updates and shift patterns.
  • Dependability and strong work ethic, including punctuality and consistent attendance.
  • Good manual dexterity and steady hand coordination for fine assembly tasks.
  • Continuous improvement orientation — willing to suggest and adopt process improvements.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with relevant technical coursework (shop, drafting, or aviation maintenance basics).

Preferred Education:

  • Associate degree or technical certificate in Aerospace Manufacturing Technology, Aircraft Maintenance Technology (AMT), Industrial Maintenance, or equivalent trade school program.
  • Manufacturer-specific or vendor certifications for composite repair, riveting or fastening preferred.

Relevant Fields of Study:

  • Aerospace Manufacturing Technology
  • Aircraft Maintenance Technology (AMT)
  • Sheet Metal Fabrication
  • Composites Technology
  • Industrial Trades / Machining / Mechanical Technology

Experience Requirements

Typical Experience Range: 0–5 years in aircraft or precision manufacturing assembly (entry-level through skilled assembler).

Preferred: 2–4 years of hands-on aircraft airframe assembly, composite assembly, or sheet metal fabrication experience in an aerospace environment; prior exposure to AS9100 and FAA/EASA environments is highly desirable. Experience with rivet installation, torque-controlled fasteners, assembly documentation and MES/ERP systems strongly preferred.

Special considerations: candidates with active security clearances, FAA certificates or documented avionics/airframe experience may be given priority.

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