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Key Responsibilities and Required Skills for Jet Engine Manufacturer

💰 $ - $

AerospaceManufacturingEngineering

🎯 Role Definition

A Jet Engine Manufacturer role encompasses multidisciplinary responsibilities across design, production, assembly, testing, certification, and aftermarket support of aero engines (turbofan, turbojet, turboshaft). Professionals in this domain ensure engines meet stringent aerospace safety, performance, and regulatory standards (FAA/EASA), applying advanced engineering, manufacturing processes, quality systems (AS9100/ISO 9001), and metallurgical treatments to produce high-reliability propulsion systems for commercial and defense markets.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Bachelor’s degree graduate in Aerospace, Mechanical, or Materials Engineering (entry-level Manufacturing/Design Engineer).
  • Aircraft engine technician or military aviation maintenance specialist transitioning to OEM manufacturing roles.
  • Certified machinist or apprenticeship program graduate entering production or assembly technician roles.

Advancement To:

  • Senior Manufacturing Engineer / Principal Engine Design Engineer
  • Program Manager – Engine Programs
  • Director of Production or Head of Engine Assembly Operations
  • Chief Engineer – Propulsion Systems, or MRO Director

Lateral Moves:

  • Test Cell Engineer / Engine Test Director
  • Supplier Quality / Supply Chain Manager
  • Reliability & Maintenance (R&M) Engineer

Core Responsibilities

Primary Functions

  • Lead detailed engine component design and integration activities using CAD tools (CATIA V5/V6, SolidWorks), ensuring rotor/stator assemblies, combustor modules, and turbine stages meet aerodynamic, structural, and thermal requirements while maintaining manufacturability and cost targets.
  • Develop and execute manufacturing process plans for high-precision parts (blisks, turbine blades, disk forgings, combustor liners) including CNC programming, finishing operations, heat treatment, and coating processes, and create process routings that achieve target cycle times and first-time quality.
  • Establish and maintain GD&T-compliant drawings and product definition packages; interpret engineering tolerances and translate them into inspection criteria, fixture designs, and operator work instructions to guarantee conformity to specifications.
  • Plan and oversee assembly and integration of engine modules and complete engines, including alignment, fastener torque sequences, shim tolerances, balancing of rotating assemblies, and installation of instrumentation for flight and ground testing.
  • Manage engine test cell campaigns from test plan creation to data capture and analysis, including run-up, performance mapping, endurance, bird strike/ice ingestion simulations, and emission testing, ensuring compliance with certification and safety protocols.
  • Execute root cause investigations for in-service and production failures using RCFA methodologies (8D, 5-Why), lead Corrective and Preventive Action (CAPA) implementation, and track results to closure with measurable quality improvements.
  • Lead supplier development and qualification efforts for critical engine components, conducting supplier audits, capability assessments, PPAP and APQP reviews, and ensuring supplier adherence to AS9100/ISO 9001 and customer-specific requirements.
  • Implement and sustain non-destructive testing (NDT) strategies—ultrasonic, eddy current, radiography, dye penetrant—and define acceptance criteria, inspection frequency, and repair limits for high-temperature and rotating components.
  • Architect and execute durability and life prediction programs, using FEA/FE models (NASTRAN, ANSYS) and fatigue analysis to validate fan, compressor, turbine, and bearing life under operational spectra and to support component replacement intervals.
  • Manage metallurgical and heat-treatment specifications for superalloys and titanium alloys (INCONEL, Ti-6Al-4V), including solution anneal, aging, stress-relief procedures, and microstructure validation through metallography to ensure creep and fatigue resistance.
  • Oversee surface engineering processes such as thermal barrier coatings (TBC), oxidation-resistant coatings, shot peening, and surface finishing to achieve required erosion and corrosion resistance for hot-section components.
  • Drive continuous improvement and Lean Manufacturing initiatives (Kaizen, SMED, 5S) on the shop floor to reduce waste, shorten lead times, improve yield, and increase throughput without compromising safety and quality.
  • Maintain configuration management and controlled documentation for designs, engineering change orders (ECOs), service bulletins, and technical publications to ensure traceability for certification and aftermarket support.
  • Coordinate cross-functional programs (engineering, procurement, quality, test, and sustainment) for new product introduction (NPI) while owning schedule, cost-of-quality, and manufacturing readiness criteria to achieve timely engine program milestones.
  • Ensure workplace safety and regulatory compliance by developing and enforcing procedures for hazardous materials handling, high-energy rotating equipment, hot-work, confined space entry, and PPE usage in accordance with environmental and occupational safety standards.
  • Lead vibration analysis and rotor dynamics assessments to identify critical speeds, balance assemblies to tight tolerances, and mitigate resonant conditions that could induce fatigue or catastrophic failure.
  • Direct repair, overhaul, and MRO activities including disassembly, inspection, repair method design, life-limited parts replacement, and documentation for serviceable return-to-service engines and modules.
  • Produce and validate engine performance models and control logic using MATLAB/Simulink or proprietary engine health management tools to support control system tuning, transient behavior analysis, and performance assurance.
  • Execute product qualification testing sequences for certification including structural static tests, thermal cycling, endurance runs, and environmental exposure tests while compiling detailed test reports and certification evidence for regulatory authorities.
  • Implement robust quality assurance programs with statistical process control (SPC), root cause trending, and corrective action closure to reduce part nonconformities and ensure consistent production of airworthy components.
  • Manage complex tolerance stacks and assembly interactions by conducting tolerance analysis and implementing design or process changes to maintain fit, function, and serviceability across the engine lifecycle.
  • Support obsolescence management and lifecycle planning by forecasting component obsolescence, developing redesigns, and coordinating supplier transitions to preserve long-term engine operability.
  • Champion digital manufacturing and Industry 4.0 initiatives, leveraging process monitoring, predictive maintenance analytics, and digital twin concepts to optimize production efficiency and reduce unplanned downtime.
  • Ensure customer-facing technical support by responding to field issues, contributing to service bulletins, and coordinating rapid-response teams for AOG (Aircraft on Ground) situations with clear SLAs.

Secondary Functions

  • Create and deliver technical training for shop floor personnel, inspectors, and assembly technicians on new processes, tooling, and inspection methods to raise competency and reduce error rates.
  • Participate in bid and proposal support—providing manufacturing cost estimates, producibility feedback, and risk assessments to secure new engine programs and aftermarket contracts.
  • Collaborate with R&D teams on advanced materials, additive manufacturing (AM) of complex geometries, and hybrid manufacturing processes to improve part performance and reduce production complexity.
  • Support corporate sustainability and waste-reduction programs by recommending material reuse, recycling strategies, and energy-efficient manufacturing technologies.
  • Assist supply chain teams with lead-time mitigation strategies, inventory optimization, and critical parts forecasting to maintain production continuity during market fluctuations.
  • Facilitate regular cross-disciplinary design reviews (DFMEA/DFR) to capture manufacturability and maintainability issues early in the development cycle and to reduce late-stage design rework.

Required Skills & Competencies

Hard Skills (Technical)

  • Deep familiarity with aero engine architectures (turbofan, turboprop, turboshaft) and subsystem interactions (fan, low/high-pressure compressor, combustor, high/low-pressure turbine, bearings, shafts).
  • Proficient in 3D CAD and data management (CATIA V5/V6, Siemens NX, SolidWorks) and model-based definition (MBD).
  • Finite Element Analysis (FEA) and structural fatigue/durability analysis experience using ANSYS, NASTRAN, or equivalent tools.
  • Computational Fluid Dynamics (CFD) experience for aerodynamic component optimization (ANSYS Fluent/CFX, STAR-CCM+).
  • GD&T expertise and ability to create and interpret complex engineering drawings and tolerance stacks.
  • Hands-on experience with CNC machining processes, CAM programming, and precision manufacturing technologies (EDM, grinding, milling, turning).
  • Metrology and inspection skills: CMM programming/operation, laser scanning, and dimensional verification techniques.
  • Non-destructive testing (NDT) certifications and practical knowledge (ultrasonic, eddy current, radiographic, penetrant) to qualify critical parts.
  • Knowledge of superalloy metallurgy, heat treatment processes, and surface engineering (TBC, coatings, shot peen).
  • Rotor dynamics and balancing experience, with tools for vibration analysis and balancing machines.
  • Engine test cell operation and instrumentation (strain gauges, thermocouples, pressure transducers, data acquisition systems).
  • Certification and regulatory knowledge (FAA, EASA, AS9100/ISO 9001 compliance), including experience compiling certification documentation.
  • Quality systems and tools: FMEA/DFMEA, PPAP, APQP, SPC, 8D problem solving, root cause analysis.
  • Additive manufacturing (AM) and hybrid manufacturing understanding for turbine/blisk production and repair strategies.
  • Software skills for modeling and control (MATLAB/Simulink, Python for data analytics, model-based systems engineering).

Soft Skills

  • Strong cross-functional communication and stakeholder management across engineering, production, suppliers, and customers.
  • Analytical problem-solving with a data-driven approach and the ability to lead structured investigations under schedule pressure.
  • Project and program management skills—planning, scheduling, risk management, and delivery focus on time, cost, and quality.
  • Leadership and team development: coach technicians and engineers, foster continuous improvement culture, and manage change.
  • Attention to detail and meticulous documentation habits required for safety-critical manufacturing processes.
  • Adaptability to fast-paced program shifts, regulatory changes, and evolving material/process technologies.
  • Customer-focused mindset with the ability to translate field feedback into design or process improvements.
  • Commercial awareness—balancing technical trade-offs with cost, lead time, and supplier constraints.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Materials Science, Manufacturing Engineering, or equivalent technical discipline.

Preferred Education:

  • Master’s degree in Aerospace/Mechanical Engineering, Materials Science, or an MBA for program/operations leadership roles.
  • Additional certifications (AS9100 Lead Auditor, Six Sigma Black/Green Belt, NDT Level II/III, PMP).

Relevant Fields of Study:

  • Aerospace Engineering
  • Mechanical Engineering
  • Materials Science & Metallurgy
  • Manufacturing/Industrial Engineering
  • Mechatronics or Control Systems Engineering

Experience Requirements

Typical Experience Range:

  • 3–10+ years of relevant aerospace or turbomachinery manufacturing experience depending on level (entry through senior).

Preferred:

  • 5+ years in jet engine OEM environment, engine test cell operations, MRO facilities, or supplier/manufacturer of critical rotating components.
  • Proven track record with AS9100-regulated production, engine certification programs, and demonstrated leadership on multi-disciplinary engine development projects.
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