Process Development Engineer

  • Location: Portsmouth, New Hampshire
  • Type: Direct Hire
  • Job #94

Now Seeking Process Engineers.

Position: Process Development Engineer
Location: Suburban Portsmouth, NH (on-site position).
Please Note: Our client does not sponsor employment visas (e.g. H-1B visa status)

Client Summary:

Our client is a global, mid-sized, leading manufacturer of advanced composite components and aerostructures for several established and emerging fixed wing, rotor wing, missile and other related airframe and engine defense and commercial platforms. Their core strength is their ability to produce highly tailored, complex composite parts and assemblies. Their products enable their customers to use lightweight, high-performance composites in applications where they previously have been restricted due to complex performance or geometry needs. Our client is growing, and this position is open due to growth.

This role includes a competitive salary, bonus plan target of 4%, and full benefits including some unique components such as unlimited PTO. Typically standard business hours Mo-Fr. Occasional evening and weekend work may be required as job duties demand.

Position Summary:
This role is responsible for composites manufacturing process design activities for advanced carbon fiber composite flight-critical aircraft components, from concepts to production-ready maturity for a development Aircraft Engine Value Stream.  The engineer is responsible for developing, verifying, and validating the processes while executing our client’s New Product Introduction (NPI) process and configuration management requirements.  The successful candidate is a creative problem solver who will effectively collaborate with other engineering disciplines and stakeholders (Operations, Program Management, etc.). The candidate hired will be responsible for mentoring junior engineers within the group.

Primary Position Responsibilities:

  • Develop textile and composite manufacturing processes, such as resin transfer molding (RTM), carbon fiber weaving, preform fabrication and forming.
  • Take moderately complex, bounded or open ended, problems from the business, develop scope options, define requirements and effectively communicate best option for stakeholder review and approval.
  • Identify Key Product and Process Requirements (KPC’s), manage control and assure compliance of them throughout product value chain.
  • Support program communication, internally and externally.
  • Provide engineering/technical recommendations for continuous improvement of processing techniques.
  • Support periodic engineering/technical project updates as needed by customer.
  • Utilize established practices for change/configuration management, documentation and continuous improvement.
  • Collaborate with engineering, quality, manufacturing, operations, and internal and external supply chain personnel to diagnose issues and support continuous improvements.
  • Perform and contribute to feasibility & trade studies, cost analysis and return on investment (ROI) and cost benefit evaluations.
  • Support achievement of project schedule and scope.
  • Organize, prepare for, and/or conduct technical design reviews to ensure conformance with engineering design and performance specifications. 
  • Support necessary engineering, verification/validation tests, and commissioning activities.
  • Drive continuous improvements in the areas of safety, quality, delivery and cost.
  • Support root cause corrective action activities using structured practices such as DMAIC, 8D, etc.
  • Perform failure mode and effects analysis (FMEA, pFMEA, dFMEA) to establish and maintain stable processes.   

Primary Position Requirement:

  • Please Note: Our client does not sponsor employment visas  (e.g. H-1B visa status).
  • Bachelor’s Engineering required (Similar technical bachelor’s degrees such as Engineering Technology, Chemistry, Physics, etc… may substitute for candidates with strong demonstrated relevant industry engineering expertise).
  • 4+ Years of Process or Manufacturing engineering is required. (Education, Internship, or Co-Op experience in composites, aerostructures, or other relevant industries will be considered.)
  • Experience with 2D laminates, RTM, VARTM, autoclave processing, fiber, fiber preforms is a plus.
  • Experience taking concepts through design, development, production, release and subsequent support is required.
  • Basic knowledge of relevant design and manufacturing standards (CHM-17, ASTM, ISO, SAE, etc.) is required.
  • Experience in the use of 3D CAD software (e.g. SolidWorks, AutoCAD, Unigraphics, Catia) is required.
  • Basic working knowledge of GD&T and dimensional stack-up analysis is required.
  • Familiarity with PLM tools (Windchill is a plus) and MRP/planning methodologies required (SAP is preferred).
  • Familiar with creation and application of process capability (Cp, Cpk) and statistical process control (SPC) tools.
  • Strong understanding of project management fundamentals and best practices is required.
  • Desire and aptitude to mentor junior engineers is required. Past related experience is a plus.
  • Background in QFD and/or Design for Six Sigma is a plus.
  • Understanding and experience with ISO9100, AS9100 or similar QMS systems preferred.
  • Optimizing process designs for manufacturability, reliability, and cost efficiency (DFx) is a plus.
  • Must be willing to travel domestically and internationally (predominantly Mexico & France) to Indoor production environment, up to ~10%.
  • Occasional evening and weekend work may be required as job duties demand.

Please Note: Our client is an affirmative action and equal opportunity employer for Minority/Female/Veteran/Individuals with a Disability. Qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, sexual orientation, gender identity, disability or protected veteran status.

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