Key Responsibilities and Required Skills for Jet Testing Operator

🎯 Role Definition

The Jet Testing Operator is an experienced technical professional who plans, executes, monitors and documents ground-based jet engine and propulsion system tests in specialized test cells. This role demands hands-on operation of start systems and auxiliary equipment, precise instrumentation and data-acquisition setup, rigorous adherence to safety and environmental regulations, and direct coordination with propulsion engineers and maintenance teams to validate system performance and support product development and certification activities.

Key SEO terms: jet testing operator, engine test cell operator, propulsion test technician, jet engine testing, test cell operations, data acquisition for engine testing, test instrumentation, engine run procedures.

📈 Career Progression

Typical Career Path

Entry Point From:

Junior Test Cell Technician / Test Cell Assistant
Aircraft Maintenance Technician (A&P) or Avionics Technician
Mechanical or Aerospace Maintenance Apprentice

Advancement To:

Senior Jet Test Operator / Test Cell Lead
Propulsion Test Engineer / Test Cell Supervisor
Engine Performance Engineer or Flight Test Engineer

Lateral Moves:

Field Service / On-wing Test Technician
Engine Overhaul or Assembly Technician
Instrumentation & Controls Technician

Core Responsibilities

Primary Functions

Safely operate jet engine test cells and associated ground support equipment (GSE) including air starters, fuel systems, hydraulic systems, cooling systems, and emergency shutdown (ESD) consoles to conduct acceptance, performance, durability and troubleshooting runs in accordance with test plans and engineering directives.
Perform comprehensive pre-test inspections: verify mounting fixtures, cowling and shroud clearance, fuel and oil levels, bleed and purge lines, safety zones, and log pre-run checklists to ensure each test meets configured safety and operational criteria.
Install, route and verify test instrumentation (thermocouples, pressure transducers, vibration sensors, strain gauges, tachometers and flow meters) with appropriate calibration certificates; ensure sensor integrity, wiring harness routing and telemetry links for the data acquisition system.
Configure, execute and monitor automated and manual test sequences using data acquisition and control software (DAS/SCADA/PLC), log real-time engine parameters (EGT, N1/N2, torque, fuel flow, oil pressure, vibration) and validate data quality for engineering review.
Execute controlled engine start, acceleration, steady-state and shutdown sequences following standard operating procedures (SOPs), safe work permits and test-specific risk assessments; manage fuel flow and ignition systems during transient events.
Record, annotate and deliver detailed test reports and run cards capturing anomalies, parameter excursions, maintenance actions, and time-stamped events; provide immediate verbal/hands-on feedback to engineering and maintenance when unsafe trends occur.
Perform first-line troubleshooting on instrumentation, engine systems and test cell controls to isolate causes of test anomalies, coordinating with propulsion engineers and the maintenance team for repairs or corrective actions.
Conduct post-test inspections including borescope checks, oil/fuel sampling and analysis, fastener torque verification, and leak checks; document the condition of hardware and submit non-conformance reports when required.
Maintain and calibrate test cell tools and portable instrumentation in collaboration with calibration labs; ensure traceability of measurement devices and adherence to calibration schedules and ISO/AS standards.
Manage fuel handling operations in compliance with environmental and hazardous materials regulations, including refueling operations, fuel sampling, waste fuel capture, and maintaining required spill response equipment and documentation.
Execute vibration surveys and NVH checks using accelerometers and spectrum analyzers; interpret vibration signatures to detect rubs, bearing faults, or structural resonance during test runs and escalate findings for engineering evaluation.
Implement test cell safety controls such as blast shields, fire suppression readiness checks, fuel and electrical isolation verifications, and established safe distances for observers during high-power runs or failure mode testing.
Coordinate and schedule test activities across multidisciplinary teams (propulsion engineers, flight test, maintenance, instrumentation, quality assurance, safety) to optimize cell utilization and improve repeatability and throughput.
Follow and contribute to continuous improvement initiatives: update procedures, capture lessons learned, and recommend hardware or instrumentation upgrades to increase test fidelity and reduce test cycle time.
Support certification and acceptance testing programs by executing formal test points, recording certified data packages, and maintaining documentation integrity for regulatory audits and customer reviews.
Provide hands-on training and mentorship to junior test technicians and temporary test crews on test procedures, safety protocols, and data acquisition best practices to ensure consistency across shifts.
Execute emergency procedures promptly (engine shutdown, fire suppression activation, personnel evacuation) and participate in regular emergency drills, maintaining readiness and clear knowledge of ESD and fire suppression systems.
Manage test cell consumables and spare parts inventory (sensors, fittings, hoses, fasteners) and initiate procurement requests to minimize test delays due to equipment shortages.
Interpret technical drawings, piping & instrumentation diagrams (P&IDs), electrical schematics and test plans to ensure correct setup and compliance with engineering intent before and during test activities.
Contribute to root-cause analyses following test failures by replicating failures, capturing exhaustive parameter sets, and collaborating on corrective actions with engineering and maintenance teams.
Enforce quality control checkpoints during instrument installation, engine installation, and test execution to ensure all outputs meet customer and regulatory specification limits and internal quality standards.
Maintain accurate logbooks, calibration records, and test archives with searchable metadata to support traceability, reproducibility and data-driven decision-making for design improvements.
Support on-wing, field, or prototype testing as required, including set-up of portable instrumentation and remote telemetry links, while ensuring test procedures are adapted safely to non-cell environments.
Participate in design reviews and test planning meetings to provide practical operational insight into test feasibility, safety constraints and expected data collection needs to influence test design.

Secondary Functions

Assist engineers in creating and refining test procedures, checklists and run cards to improve clarity, safety and repeatability for complex test campaigns.
Support data validation and initial processing workflows to prepare datasets for engineering analysis, ensuring timestamps, channel labels and units are standardized.
Participate in cross-functional continuous improvement teams to develop better cell utilization metrics, reduce test turnaround times, and eliminate recurring failure modes.
Contribute to the development and maintenance of training materials, competency checklists and certification records for test cell operators.
Help manage test cell access, scheduling and contractor coordination to ensure only qualified personnel operate or observe active tests.

Required Skills & Competencies

Hard Skills (Technical)

Engine test cell operation: safe start/stop sequences, emergency shutdown procedures, cell safety systems operation.
Test instrumentation installation and calibration (thermocouples, pressure transducers, accelerometers, strain gauges).
Data acquisition systems and software experience (DAQ, LabVIEW, National Instruments, CATMAN, MATLAB, or equivalent).
Engine parameter interpretation: EGT, N1/N2, torque, fuel flow, oil pressure, temperatures and vibration signatures.
Vibration and NVH measurement tools and spectrum analysis techniques.
Troubleshooting mechanical, fuel, ignition and electrical subsystems under test conditions.
Reading and interpreting technical drawings, wiring diagrams, P&IDs and test procedures.
Portable borescope inspection and visual inspection techniques; familiarity with NDT basics (dye penetrant, eddy current, ultrasonic) is a plus.
Fuel handling, hazardous materials awareness, and spill prevention controls (HAZMAT/OSHA best practices).
Use and maintenance of ground support equipment (air starters, pneumatic/hydraulic test stands, load cells).
Calibration management and record-keeping with traceable measurement standards.
Test safety, risk assessment and permit-to-work procedures for high-energy systems.
Experience with engine run-up rigs, thrust stands, torque measurement and performance instrumentation.
Basic PLC/SCADA or control console interaction for test automation and safety interlocks.

Soft Skills

Strong attention to detail and process discipline to ensure repeatable, valid test results.
Clear, concise technical communication—both written test reports and verbal coordination under pressure.
Team collaboration across engineering, maintenance, QA and safety teams.
Problem-solving mindset with methodical troubleshooting and logical root-cause analysis.
Time management and prioritization in high-utilization test schedules.
Adaptability and calm decision-making during abnormal or emergency test conditions.
Teaching and mentoring aptitude to upskill junior technicians and contractors.
Quality-focused orientation and ownership of test deliverables.
Proactive safety leadership and willingness to halt tests when safety is compromised.
Continuous improvement mentality with an eye for process optimization and cost-effective solutions.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with relevant technical coursework or vocational certification in aircraft maintenance, mechanical technology, or instrumentation.

Preferred Education:

Associate degree or Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Aviation Maintenance Technology or Instrumentation & Controls.
FAA A&P certification, military aviation maintenance experience, or equivalent hands-on propulsion experience preferred.

Relevant Fields of Study:

Aerospace or Mechanical Engineering
Aviation Maintenance Technology (A&P)
Instrumentation & Controls / Mechatronics
Industrial or Manufacturing Technology
Physics or Applied Science with hands-on lab experience

Experience Requirements

Typical Experience Range:

2–7 years of hands-on experience operating engine test cells, propulsion testing facilities, or aircraft engine maintenance and run operations.

Preferred:

5+ years operating jet engine test cells or equivalent propulsion test experience, with demonstrated ability to run complex test campaigns, manage instrumentation suites, and produce certified test data packages.
Prior experience in a regulated aerospace or defense environment, supporting certification, reliability or flight test programs.