Key Responsibilities and Required Skills for Jet Engine Assembler

🎯 Role Definition

The Jet Engine Assembler is a skilled technician responsible for precision assembly, inspection, test and documentation of commercial and military jet engines and core engine components. This role requires deep familiarity with aerospace standards (AS9100, FAA), hands-on expertise with precision tools and fixtures, the ability to read and interpret engineering drawings and work instructions, and the discipline to maintain strict quality, safety and FOD (foreign object debris) controls. The assembler works cross-functionally with quality, engineering, supply chain and test cell teams to deliver airworthy engines that meet performance and reliability targets.

📈 Career Progression

Typical Career Path

Entry Point From:

Aircraft Maintenance Technician (A&P) transitioning into manufacturing assembly.
Aerospace Assembler or Production Technician with general aircraft experience.
Precision Machinist / Tool and Die Technician moving into assembly of rotating hardware.

Advancement To:

Senior Jet Engine Assembler / Lead Assembler overseeing cell operations.
Engine Test Technician or Test Cell Operator managing run schedules and instrumentation.
Quality Inspector / Non-Destructive Testing (NDT) Specialist focused on engine components.
Assembly Supervisor, Manufacturing Engineer or Continuous Improvement (CI) Engineer.

Lateral Moves:

NDT Technician (Level II) specializing in eddy current or dye penetrant methods.
Material Planner or Supply Chain Coordinator for engine components.

Core Responsibilities

Primary Functions

Perform complete assembly of turbofan/turboprop engine modules and accessory gearboxes by following detailed work instructions, route cards and engineering drawings while applying best practices for torqueing, sealing, and fastening to OEM specifications.
Interpret and apply engineering blueprints, wiring diagrams and bill of materials to accurately position and assemble blades, vanes, stators, rotors, diffusers, housings and casings with required clearances and blade tip-to-case tolerances.
Execute precision measurement and inspection using micrometers, calipers, bore gauges, dial indicators and surface plates to verify dimensional conformity and record results in manufacturing systems.
Apply correct torque procedures, calibration values and calibrated torque tools to fasteners, studs and bolted assemblies while documenting torque-out and verification evidence per quality standards.
Install, balance and dynamically trim rotating assemblies (rotors, spools, impellers) using balancing machines and vibration analysis procedures to meet engine NVH and rotor balance specifications.
Conduct pre-assembly cleaning, degreasing and FOD control procedures to ensure contamination-free environments for fuel, oil and compressor sections; maintain housekeeping and traceability of clean rooms or controlled areas.
Perform mechanical joining processes including riveting, blind fastener installation, interference fits, press-fit operations and light structural welding/brazing where applicable, following welding procedure specifications (WPS).
Complete routine and special non-destructive inspections (visual, dye penetrant, eddy current) and escalate findings to Quality/NDT personnel for dispositions, ensuring all indications are dispositioned before proceeding.
Execute functional and leak tests on fuel systems, oil systems, and pneumatic lines using calibrated gauges and test fixtures to verify seals, pressures and flow paths meet engineering acceptance criteria.
Troubleshoot assembly discrepancies and nonconformances, perform root-cause analysis in collaboration with engineering, and implement corrective actions or rework under documented approvals.
Maintain accurate process documentation including Traveler/Work Order completion, First Article Inspection (FAI) records, assembly checklists, and electronic work instructions in SAP/MRP systems to ensure traceability and audit readiness.
Participate in engine build flows and final assembly processes at paced workstations to meet production schedules while maintaining zero-defect quality targets and on-time delivery metrics.
Setup and operate specialty assembly tooling and fixtures including hoists, torque multiplies, presses, and custom jigs while ensuring tool calibration and maintenance are up to date.
Collaborate with design and manufacturing engineers to execute engineering change notices (ECNs), implement process improvements and update assembly methods where necessary to improve yield and reduce cycle time.
Support in-process statistical process control (SPC) by collecting dimensional and performance data, identifying trends, and recommending countermeasures to maintain process capability.
Participate in engine run-ups and static testing activities as assigned, assisting test cell personnel with instrumentation hookups, data recording and operational checks while following strict safety protocols.
Ensure compliance with aerospace quality standards such as AS9100, NADCAP requirements and customer-specific standards, and support internal and external audits by preparing and providing required evidence.
Mentor and train junior assemblers and apprentice technicians on assembly techniques, safety practices, and quality expectations to build team capability and cross-training capacity.
Implement and promote lean manufacturing practices, 5S, Kaizen events and continuous improvement initiatives to drive efficiency and reduce waste on the engine assembly floor.
Manage component kitting and pre-assembly preparation, verifying parts against packing lists and BOMs, and coordinating with receiving/warehouse to resolve material discrepancies quickly.
Report safety incidents, near misses and process abnormalities, and actively participate in safety reviews and daily pre-shift briefings to maintain a culture of safety and compliance.

Secondary Functions

Maintain and update tooling calibration logs and assist maintenance with preventative maintenance on assembly fixtures and handling equipment.
Support technical documentation updates by providing field feedback to engineering on assembly issues, tooling ergonomics, and process clarifications.
Assist quality and supply chain teams during incoming inspections and supplier nonconformance investigations that directly impact assembly operations.
Participate in cross-functional problem-solving workshops to address yield losses, supplier quality, and assembly rework drivers.
Support continuous training initiatives by developing standard work aids, visual controls and operator checklists to improve first-pass yield.
Help prepare engines for shipping including preservation, packaging and labeling to meet customer export and packing specifications.
Act as a point of contact for temporary production line changes during peak builds or product transitions, ensuring communication flows to relevant stakeholders.

Required Skills & Competencies

Hard Skills (Technical)

Precision assembly of turbofan and turboprop engine components, including rotor/stator installation and spool assembly.
Reading and interpreting mechanical drawings, GD&T symbols and engineering specifications for complex rotating machinery.
Proficient use of precision measurement tools: micrometers, calipers, bore gauges, dial indicators and height gauges.
Applied knowledge of torque values, torque sequencing, calibrated torque tools and bolting procedures for aerospace hardware.
Operation and setup of balancing machines, dynamic balancing techniques and basic vibration measurement fundamentals.
Non-Destructive Testing basics and coordination (visual inspection, dye penetrant, eddy current) and experience working with NDT personnel.
Hands-on experience with riveting, blind fastener installation, light brazing, and use of presses and specialty joining equipment.
Familiarity with AS9100 quality system requirements, NADCAP principles and compliance to aerospace manufacturing standards.
Experience with engine test cell support: instrumentation hookups, leak checks, run-up procedures and test data logging.
Working knowledge of shop floor systems: SAP, MRP/ERP, electronic work instructions, and manufacturing data entry for traceability.
Understanding of materials commonly used in engines: titanium, nickel alloys (Inconel), stainless steels and composite component handling.
Strong FOD control practices, clean-room or controlled-environment assembly experience and contamination prevention techniques.
Root cause analysis methods (5 Whys, Fishbone) and formal corrective action request (CAR) process participation.
Basic mechanical troubleshooting and ability to read wiring schematics for accessory and fuel systems.

Soft Skills

Exceptional attention to detail with a commitment to zero-defect manufacturing and adherence to quality standards.
Strong manual dexterity and steady hand coordination for precision tasks under microscopes or in confined spaces.
Excellent communication skills to clearly document findings, escalate issues and collaborate with engineering and quality.
Problem-solving mindset with the ability to investigate, propose corrective actions and follow through to resolution.
Time management and organizational skills to balance paced production demands with quality verification steps.
Team player attitude with experience working in cross-functional environments and shift-based manufacturing teams.
Adaptability to changing priorities, engineering changes and production schedules in a high-mix, high-reliability environment.
Coaching and mentoring ability to transfer skills to less-experienced technicians and support structured training programs.
Strong safety orientation and accountability for personal and team compliance with safety and environmental regulations.
Continuous improvement mindset and willingness to participate in Lean/Kaizen events to improve flow and reduce cycle time.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with strong emphasis on math and technical shop classes.

Preferred Education:

Associate degree, vocational certificate or technical diploma in Aerospace Manufacturing, Aviation Maintenance, Precision Machining, or Mechanical Technology.

Relevant Fields of Study:

Aerospace Manufacturing Technology
Aviation Maintenance Technology (A&P)
Machine Tool Technology / Precision Machining
Mechanical Engineering Technology
Industrial Maintenance / Manufacturing Technology

Experience Requirements

Typical Experience Range:

2 to 5 years of hands-on assembly experience in aerospace, power generation or related precision manufacturing environments.

Preferred:

5+ years of direct jet engine or gas turbine assembly experience, with demonstrated experience in turbofan/turboprop builds, balancing, and engine test support; AS9100 and NADCAP exposure and NDT coordination preferred.