Process Lead Engineer For Additive Manufacturing

Honda Aero, Inc. in Burlington, NC is in search of a Process Lead Engineer for Additive Manufacturing (AM) who will lead the development, implementation, and improvement of Additive Manufacturing processes for aero engine components. Responsible processes include Additive Manufacturing and AM post processes such as heat treatment, machining, surface finishing and more. Multiple engineering skills such as manufacturing process establishment, process control, and engineering plan, do check, act (PDCA) are required.

The role also requires purchase and maintenance of the equipment required for processes using existing company systems.

In addition, it is expected to consider manufacturing plans and create process control documents to meet requirements from external aviation industry standards and internal standards to prepare for future production. Future readiness will require a project environment including other departments such as Quality, Parts manufacturing, and IT team. Working with teams as a project leader will require strong interpersonal and leadership skills.

*Key word for Abilities: Creativity, Flexibility, Persistence, Contribution, Challenging spirit, Project management and communication, leadership, certification.

Key responsibilities:

[AM process]

• Generate or approve AM build layouts to deliver high build success rates.
• Setup AM build job and run AM machines correctly and clearly document information.
• Review and interpret 3D data and provide feedback to design engineers in USA & Japan.
• Create and execute test plans while utilizing Plan, Do, Check, Act (PDCA) cycle.
• Analyze, collaborate and understand Additive Manufacturing build failure events to implement countermeasures for future builds.
• Develop knowledge base and understanding for in-situ (live) monitoring of AM machine builds.
• Manage an inventory of parts, powder and maintenance records.
• Establish and manage process conforming to regulations and specifications.
• Involvement with industrial & regulatory working groups such as FAA/EASA, ASTM, America Makes, and SAE.

[Project management]

• Identify necessary tasks to meet project objectives.
• Plan and manage timeline of tasks related to AM and post processes to meet project goal.
• Participate and lead weekly meetings and effectively communicate with project leader and team members.
• Establish necessary environment with coordinating other departments and external organizations/suppliers.
• Periodically present project status or requests to senior and executive leadership.
• Establish process in ERP systems.

[Others]

• Operate different types of equipment such as: wire EDM, band saw, CNC machines and hand tools as required.
• Maintain a clean and safe working environment.
• Work in an international team environment and provide solutions to manufacturing struggles.
• Attend on-site and off-site training as well as conferences as required.

QUALIFICATIONS, EXPERIENCE, & SKILLS

Minimum Educational Qualifications

• Bachelor's degree in mechanical engineering, Materials Engineering, Chemical Engineering or equivalent experience.

Minimum Experience

• Minimum of three (3) years of industrial experience.
• Experience with Additive Manufacturing principles and welding technologies.
• Experience with CAD software and interpretation of engineering specifications/drawings is preferred.
•  Experience with ERP systems.
• Experience leading small/medium sized projects of multiple departments and backgrounds.

Other Job-Specific Skills

• Strong hands-on ability and critical thinking skills.
• Willingness to balance hands on work (in the lab) and engineering work (at the desk).
• Ability to not only follow but also create directions and standard operating procedures.
• Ability to troubleshoot system issues and report detail to engineering team.
• Ability to generate a strategy and independently think without input from supervisors.
• Analytical ability to perform research tasks and create engineering test plans/reports as a part of R&D activities.
• Organizational skills with strong attention to detail and quality.
• Oral and written communication skills including proficiency in MS Office software.
• Strong computer proficiency (work with many different software programs/analysis)
• Strong multi-tasking skills are essential to work on many projects at once.

Physical Requirements/Work Conditions

• Climate-controlled production environment
• Regular exposure to the manufacturing areas which under certain circumstances require the use of personal protective equipment such as safety glasses with side shields, mandatory hearing protection and safety shoes
• Ability to frequently stand, walk, and sit as well as regular use of hands, fingers, and arms
• Ability to lift up to 30 pounds.