Lead Manufacturing Engineer – NPI (Composites)

IF1200 GE Aviation Systems Limited; Gloucester; On-site; GBP 65,000 - 95,000; Full time

Benefits offered by this job

FlexChoice benefits

Private medical cover

Pension

Holiday 26 days

Relocation assistance

Job summary

Dowty, a GE Aerospace company, Gloucestershire, UK, is seeking a Lead Manufacturing Engineer to drive the team turning advanced composite designs into real hardware and a repeatable production process. You will steer manufacturing engineering from development builds through low-rate production, shaping design early and ensuring readiness across processes, people, and equipment.

You will lead development hardware, apply PFMEAs, control plans and PFMEAs, and work with cross-functional teams to

Qualifications

• Engineering degree or equivalent experience.
• Strong manufacturing engineering background with composites.
• Experience leading engineers in manufacturing.
• Experience with NPI from development to production.
• Experience in equipment specification, supplier engagement and commissioning.
• Ability to create work instructions, routings and operator training.
• Lean/Six Sigma/8D problem solving and data-driven influence.
• Knowledge of GD&T, CAD tools and automation.

Responsibilities

• Lead a team of manufacturing engineers and provide technical direction.
• Drive NPI processes including planning, gate readiness and delivery.
• Champion PFMEAs and control plans; cascade critical characteristics.
• Define facility requirements for in-line process control and ramp-up readiness.
• Lead development hardware and transition to low-rate production; troubleshoot issues using data.
• Develop composite process knowledge and test routines for new tech.
• Promote failure mode avoidance in future designs and equipment specs.
• Contribute to lean solutions, value engineering, and capital investment cases.
• Ensure training and work instructions are prepared for operators.

Skills

Leadership

Problem solving

Data-driven decisions

Lean Six Sigma

Cross-functional collaboration

Project management

Education

Engineering degree

Tools

CATIA

AutoCAD

NDT

Virtual manufacturing tools

Job description

Job Description Summary

Help bring propeller expertise to the future of flight. Here at Dowty, a GE Aerospace company, we design, manufacture, repair and overhaul propeller systems for Military and Civil applications from our state-of-the-art facility in Gloucestershire, UK. Our propeller expertise is now helping inform the development of Open Fan technology, one of the next-generation propulsion architectures being matured through the CFM RISE program. As Lead Manufacturing Engineer, you will lead the team that turns advanced composite designs into real hardware, and then into a capable, repeatable production process. You’ll drive the manufacturing engineering agenda from development builds through to low rate initial production, influence design early, and make sure the processes, people and equipment are ready for the next stage of ramp-up.

Job Description

Help bring propeller expertise to the future of flight. At Dowty, a GE Aerospace company, we design, manufacture, repair and overhaul propeller systems for Military and Civil applications from our state-of-the-art facility in Gloucestershire, UK. Our propeller expertise is now helping inform the development of Open Fan technology, one of the next-generation propulsion architectures being matured through the CFM RISE program. As Lead Manufacturing Engineer, you will lead the team that turns advanced composite designs into real hardware, and then into a capable, repeatable production process. You’ll drive the manufacturing engineering agenda from development builds through to low rate initial production, influence design early, and make sure the processes, people and equipment are ready for the next stage of ramp-up.

What you’ll lead

Your team Lead and mentor a team of manufacturing engineers, providing technical direction, guidance and support to make sure the program succeeds. Delegate effectively while staying accountable for your team’s deliverables. Build strong collaboration and communication within the team and across departments, acting as the point of contact between the NPI team and support functions to coordinate the manufacturing engineering agenda. The NPI process Lead the team in following the NPI process and ensure adherence to it, including project planning, gate readiness and delivery. Champion APQP and PPAP within NPI. Drive the creation of PFMEAs and control plans, and cascade critical characteristics into internal and supplier quality operating systems. Define the facility requirements for in-line process control, so the process is demonstrably capable on site and across the supply chain. Development hardware and low rate initial production Lead the manufacture of development hardware, and take a hands-on role in trials that validate processes and technologies. Lead the transition into low rate initial production. Resolve manufacturing engineering issues using data, rationale and logic, working directly with manufacturing and engineering teams as problems arise. Composite process development Apply your composite manufacturing knowledge to develop test routines that establish process parameters for new technologies and processes, and to determine whether designed solutions are feasible. Work with the current product manufacturing engineering team and materials & process engineers to promote failure mode avoidance in future designs and equipment specifications, and to shape our combined industrialisation strategy. Ramp-up readiness Enable the ramp-up that supports the next stage of the program, combining structured problem solving, process optimisation and efficient use of resources. Ensure that process capability, cycle time and equipment availability targets are achievable, through automation, existing solutions or new technology. Make sure your team delivers the work instructions, routings and supporting documentation that operators need to be trained and to build with confidence. Stay on top of training readiness, working with Operations to identify and plan training needs (production, manufacturing engineering and maintenance) ahead of ramp-up. Design influence Make sure manufacturing is represented throughout product development, and treat design for manufacture and assembly as a priority for the life of the program. Tooling, equipment and facility Lead your team in the design and acquisition of the tooling used for each design iteration, working with suppliers and the internal Sourcing team. Provide process expertise to support equipment design and acquisition, working alongside the teams delivering it. Contribute to defining equipment lists, spares requirements, and substance and equipment safety documentation. Act as the process subject matter expert during installation and commissioning, helping systems meet requirements for safety, quality, delivery and cost (SQDC). Support compliance with health & safety and CDM regulations in process and equipment design. Advise on optimised cell layouts, value stream maps, timing charts and process flow diagrams developed with other teams, helping drive robust lean solutions that maximise ROI and reduce hours and cost per unit. Provide process input to virtual manufacturing simulations, making sure they accurately reflect workflow, automation sequences and space requirements, to inform capacity plans, resource requirements, line balancing and investment cases. Support value engineering activities and make/buy decisions on core and non-core parts. Contribute process expertise to the blueprint for a scalable production facility.

What you’ll bring

An engineering degree (or equivalent experience) and a track record in manufacturing engineering. Strong, practical knowledge of composite manufacturing processes and tooling. Experience leading engineers in a manufacturing environment. Experience of NPI, from development builds through to initial production. Experience of equipment and tooling specification, supplier engagement and commissioning. Experience preparing a process for production, including work instructions, routings and operator training. A structured approach to problem solving (Lean, Six Sigma, 8D) and the ability to influence with data. It would be great if you also have Experience in a regulated industry such as aerospace. CAD experience (CATIA or AutoCAD) and an understanding of GD&T. Knowledge of NDT, automation, or virtual manufacturing and simulation tools. Familiarity with H&S and CDM requirements for new equipment installations.

Why join us

Work that matters. Help shape the next generation of propulsion technology, with real influence over design, process and facility decisions. A modern site. Be part of our state-of-the-art facility in Gloucestershire. Flexible Working GE supports and encourages flexible working arrangements, where possible, and recognises the benefits to employees of having a positive work-life balance. Total Reward At GE Aerospace we understand the importance of Total Reward. Our flexible benefits plan, called FlexChoice, gives you freedom, choice and flexibility in the way you receive your benefits, as well as giving you the opportunity to make savings where possible. As a new joiner to GE we are pleased to be able to offer you the following as default in your benefit fund, which you then can tailor to meet your individual needs; Non-contributory Pension Life Assurance Group income protection Private medical cover Holiday Hourly equivalent of 26 days, with flexible option to buy or sell

Security Clearance

Baseline Personnel Security Standard (BPSS) clearance is required and must be maintained for this role. Please note that in the event that BPSS clearance cannot be obtained, you may not be eligible for the role and/or any offer of employment may be withdrawn on grounds of national security. Please see the link below for further details regarding the requirements for BPSS clearance: BPSS

BPSS Right to Work

Applications from job seekers who require sponsorship to work in the UK are welcome and will be considered alongside all other applications. However, under the applicable UK immigration rules as may be in place from time to time, it may be that candidates who do not currently have the right to work in the UK may not be appointed to a post if a suitably qualified, experienced and skilled candidate who does not require sponsorship is available to take up the post. For further information please visit the UK Visas and Immigration website.

Additional Information

Relocation Assistance Provided: Yes At GE Aerospace, we invent the future of flight, lift people up, and bring them home safely. We are a world-leading provider of jet engines, components, and integrated systems for commercial and military aircraft. At GE Aerospace, respect for people is core to our culture and commitment to FLIGHT DECK, our proprietary lean operating model. We attract, develop, and retain industry-leading talent from all backgrounds and cultivate communities where people are respected and empowered to reach their fullest potential. For the people of GE Aerospace, their work isn't just a job. It's their passion and purpose. We work and win as one team, accountable to each other and our customers, and we are always finding a better way to climb higher together. We were meant to fly.