Key Responsibilities and Required Skills for Jet Engine Tester Assistant

🎯 Role Definition

The Jet Engine Tester Assistant supports engine test cell operations and field testing activities for turbine engines, turbojets, turbofans, and auxiliary power units. This role performs pre-test preparations, assists with engine start/run sequences, monitors instrumentation and data acquisition systems, documents performance and anomalies, and executes routine mechanical tasks under the direction of senior test engineers and test cell supervisors. Emphasis is placed on safe execution, accurate data capture, thorough inspections, and timely communication of test results and discrepancies.

This position is ideal for technicians with hands-on mechanical experience, familiarity with instrumentation/DAQ, and an understanding of engine performance parameters such as thrust, EGT, N1/N2, fuel flow, and vibration signatures.

📈 Career Progression

Typical Career Path

Entry Point From:

Aerospace Technician / Aircraft Mechanic (A&P)
Mechanical Technician / Maintenance Technician
Test Cell Operator Trainee or Laboratory Technician

Advancement To:

Engine Test Cell Operator / Senior Test Technician
Test Engineer / Performance Engineer
Engine Maintenance Planner or Overhaul Supervisor

Lateral Moves:

Flight Line Technician / Line Maintenance
Vibration Analyst / Condition Monitoring Specialist

Core Responsibilities

Primary Functions

Assist in the setup and safe preparation of jet engine test cells, including mounting engines to test fixtures, connecting fuel and oil systems, hooking up instrumentation, and verifying all control and safety interlocks prior to engine start.
Execute pre-test inspections and comprehensive checklists (mechanical, electrical, fuel, lubrication, bleed air and cooling systems) to confirm readiness and document any non-conformances with clear photos and notes for follow-up.
Support engine start-up and shutdown procedures under direction, monitoring key engine parameters (N1, N2, EGT, fuel flow, oil pressure, RPM, thrust) and maintaining continuous situational awareness to react to anomalies or emergency shutdown conditions.
Operate and maintain test instrumentation and data acquisition systems (DAQ), ensuring sensors, thermocouples, pressure transducers, tachometers and accelerometers are calibrated, installed correctly, and recording data at required sampling rates.
Record and log test data in standardized formats, verify data integrity, and produce initial run cards and test logs for review by test engineers; flag data irregularities and assist in root-cause data review sessions.
Perform routine mechanical tasks such as engine fastening/torqueing, hose/line installation, rigging of mounts, alignment checks, and basic adjustments to ensure mechanical integrity during runs.
Conduct hot and cold inspections, borescope-assisted internal inspections, and post-run visual checks to identify wear, foreign object damage (FOD), leakage points, and thermal distress; document findings and assist with disposition.
Monitor and enforce test cell safety protocols, including fuel handling, hot work permits, confined-space procedures, noise and hearing conservation, and emergency response plans; actively participate in safety briefings and pre-run risk assessments.
Assist in vibration monitoring and analysis during runs, capturing time-domain and frequency-domain data, tagging events, and working with vibration analysts to isolate sources of resonance or abnormal signatures.
Troubleshoot instrumentation, cabling, and sensor failures, performing bench checks, continuity tests, and simple repairs or swaps to minimize downtime while escalating complex issues to instrumentation engineers.
Support fuel system checks and fuel control calibrations, including flushing, filter changes, priming pumps, and confirming correct fuel flow and pressures prior to and during runs.
Handle and prepare test fluids, oils, and consumables to specifications, maintain proper containment and disposal practices, and keep accurate inventory records of test supplies.
Assist with test rig modifications, tooling fabrication, and temporary fixtures using hand and power tools; follow engineering drawings and change requests while maintaining configuration control.
Maintain test cell housekeeping, ensuring loose objects are secured, FOD prevention practices are followed, and engine plenum and exhaust areas are inspected and cleaned between tests.
Execute engine break-in and bench testing sequences, supporting step-wise run schedules, transient testing (accelerations, decelerations, throttle steps), and endurance runs per engineering procedures.
Participate in test planning meetings, contribute practical insights on setup duration and resource needs, and help coordinate logistics between engineering, production, and quality teams.
Assist in the collection of ancillary measurements (ambient conditions, humidity, barometric pressure, inlet conditions), and ensure environmental corrections are applied to performance data where required.
Prepare and assemble test documentation packages, including run cards, NCRs, serviceable/non-serviceable tags, and initial draft run reports for review and finalization by the test engineer.
Conduct basic electrical checks on engine-mounted sensors, harnesses, and junction boxes, ensuring signal integrity and proper grounding to reduce noise in measurement channels.
Support post-test teardown and removal of engines from test stands, participate in disassembly for inspection, and coordinate transport or secure storage in line with maintenance and safety policies.
Assist with calibration tracking and coordinate with calibration labs to schedule sensor and instrumentation calibration to maintain traceability and audit readiness.
Provide hands-on support during anomaly investigations: collect supplemental data, replicate failure modes when safe, and assist senior staff in implementing corrective actions and test reruns.
Ensure compliance with regulatory standards and company quality systems (FAA/EASA guidance where applicable), maintaining accurate records to support airworthiness and audit activities.
Mentor and train junior technicians on test cell best practices, safe handling of turbine engines and instrumentation, and standardized documentation to build team capability.

Secondary Functions

Coordinate with production, quality, and engineering to schedule tests and communicate engine availability and run results.
Help maintain and update run sequence scripts and automated test procedures in support of continuous improvement.
Contribute to root-cause analyses by preparing annotated datasets, supporting lab tests, and organizing physical evidence for engineering review.
Participate in small continuous improvement initiatives to reduce setup time, improve data quality, and standardize tooling or checklists.
Support ad-hoc tooling fabrication and low-risk mechanical modifications under supervision, contributing to test cell adaptability.
Assist with training documentation and practical demonstrations of test procedures for new hires and temporary staff.
Help track equipment maintenance intervals and raise work orders for cell infrastructure (exhaust, fuel piping, HVAC) when defects are discovered.

Required Skills & Competencies

Hard Skills (Technical)

Proficient in engine test cell operations, including engine mounting, start/stop sequences, and run card execution for turbojet/turbofan engines.
Experience with data acquisition systems and test instrumentation (e.g., National Instruments DAQ, LabVIEW test sequences, Strain gauges, thermocouples, pressure transducers).
Hands-on mechanical aptitude: torqueing fasteners, rigging, hose and line work, use of calibrated torque wrenches and common maintenance tools.
Basic electrical and sensor troubleshooting skills: continuity testing, signal verification, and simple harness repairs.
Familiarity with vibration monitoring and basic FFT analysis workflows; ability to capture event markers and support vibration engineers.
Competence in reading and following engineering drawings, wiring diagrams, P&IDs and test procedures.
Experience with engine performance parameters and instrumentation: N1/N2, EGT/ITT, fuel flow, oil pressure, thrust measurement systems.
Familiarity with borescope inspection techniques and reporting; able to assist in internal inspections and capture quality imagery.
Knowledge of fuel system checks, priming procedures, filter changes, and safe handling of aviation fuels and test fluids.
Proficient with Microsoft Office, data logging software, and basic data analysis tools (Excel, MATLAB or Python familiarity is a plus).
Understanding of calibration requirements and basic coordination for sensor and instrument calibration activities.
Experience maintaining configuration control and basic familiarity with quality systems (ISO, FAA/EASA related processes).

Soft Skills

Strong attention to detail and accuracy in documentation and measurement capture.
Excellent verbal and written communication skills for shift handovers, test logs, and multidisciplinary coordination.
Ability to work effectively in a high-pressure environment and remain focused during critical engine runs.
Team-oriented mindset with willingness to support colleagues across shifts and collaborate with engineers and safety teams.
Problem-solving aptitude and calm decision-making during anomalies and emergency shutdown conditions.
Proactive safety focus: recognizes hazards, follows lockout/tagout, and promotes a safety-first culture.
Good time management and organizational skills to prioritize setup, tests, and post-test activities.
Willingness to learn and adapt to evolving test procedures, instrumentation updates, and industry best practices.

Education & Experience

Educational Background

Minimum Education:

High school diploma or equivalent with vocational/technical training in aircraft maintenance, mechanical technology, or related field.

Preferred Education:

Associate degree or diploma in Aviation Maintenance Technology, Aerospace Engineering Technology, Mechanical Engineering Technology, or similar.
FAA Airframe & Powerplant (A&P) certification or equivalent national licensing is highly desirable.

Relevant Fields of Study:

Aerospace / Aviation Maintenance
Mechanical Engineering Technology
Instrumentation & Control Technology
Electrical Technology / Electronics

Experience Requirements

Typical Experience Range: 1–5 years of hands-on experience in aerospace maintenance, engine testing, or industrial mechanical/test environments.

Preferred:

2+ years supporting jet engine or gas turbine testing in a test cell or flight line environment.
Experience with DAQ systems, vibration monitoring, borescope inspections, and working under formal quality/safety systems (FAA/EASA/ISO).
Prior exposure to engine run scheduling, test documentation, and coordination with engineering teams.