Head- Prototype Manufacturing process & Assembly Integration

Ubifly Technologies; Chengalpattu; On-site; INR 4,000,000 - 6,000,000; Full time

Job summary

Ubifly Technologies in India seeks a Head of Prototype Manufacturing Process & Assembly Integration to lead end-to-end prototyping and scalable production. You will own prototype build strategy, manufacturing processes, tooling design, and full-aircraft integration across structures, propulsion, avionics, and systems.

The role drives DFMA reviews, SOPs, LRIP to FRP roadmaps, and automation initiatives while coordinating with design, systems, test, and supply chain teams.

Qualifications

• Bachelor's or Master's in Aerospace/Mechanical Engineering.
• Lean Six Sigma or equivalent certification preferred.
• Experience leading aerospace prototype/manufacturing initiatives.

Responsibilities

• Own strategy, planning, and execution of full-scale and sub-scale eVTOL prototype builds.
• Translate CAD/PLM outputs into manufacturable prototype build packages.
• Drive rapid iteration cycles between design, test, and manufacturing teams.
• Own final assembly line (FAL) design, sequencing, and station-by-station build strategy.
• Lead systems integration into the airframe and define tooling/automation.
• Ensure quality, safety, and regulatory compliance during integration.
• Mentor a multi-disciplinary team and manage cross-functional collaboration.

Skills

Leadership

Cross-functional

Problem solving

Stakeholder mgmt

Lean manufacturing

Kaizen

Team mentoring

Education

Aerospace Engineering

Lean Six Sigma certification

Tools

CAD/CAM

PLM

MES

Quality tools

Job description

Head- Prototype Manufacturing process & Assembly Integration

Chinglepet, India

The Head of eVTOL Prototyping, Manufacturing Process & Assembly Integration will lead the end-to-end journey of transforming aircraft design into flight-ready prototypes and scalable production. This role owns prototype build strategy, manufacturing process development, tooling/fixture design, and full-aircraft assembly integration (structures, propulsion, avionics, electrical, and systems), ensuring the eVTOL platform moves efficiently from concept to certified, production-ready aircraft.

Key Responsibilities

• Own the strategy, planning, and execution of full-scale and sub-scale eVTOL prototype builds
• Translate design engineering outputs (CAD/PLM) into manufacturable prototype build packages
• Drive rapid iteration cycles between design, test, and manufacturing teams

2. Manufacturing Process Development

• Design and industrialize manufacturing processes for airframe structures and related subsystems
• Develop process plans, work instructions, routings, and standard operating procedures (SOPs)
• Lead Design for Manufacturing & Assembly (DFMA) reviews with design engineering
• Build the roadmap from low-rate initial production (LRIP) to full-rate production (FRP)
• Select and qualify manufacturing processes specifically composite layup/curing

3. Assembly Integration

• Own final assembly line (FAL) design, sequencing, and station-by-station build strategy
• Lead systems integration into the airframe.
• Define and implement jigs, fixtures, tooling, and assembly automation
• Ensure fit, form, and function compliance during integration; resolve build non-conformances

4. Quality, Safety & Compliance

• Ensure manufacturing and assembly processes comply with aerospace quality standards & DGCA regulations
• Implement inspection plans, first article inspection (FAI), and non-conformance/CAPA processes

5. Team & Cross-Functional Leadership

• Mentor and lead a multi-disciplinary team: manufacturing engineers, prototype technicians, assembly integration engineers, tooling designers
• Partner closely with Design Engineering, Systems Engineering, Test & Flight Operations, Supply Chain, and Quality teams
• Manage relationships with external vendors, fabrication partners, and suppliers
• Own budgeting, resource planning, and program timelines for prototyping and assembly functions
• Drive lean manufacturing, 5S, and Kaizen practices on the shop floor
• Develop the strategy for scaling from prototype to series production, including facility/line planning
• Evaluate and implement automation, digital manufacturing (MES/PLM integration), and Industry 4.0 tools

Experience Required

12–18+ years in aerospace/aircraft manufacturing, prototyping, and assembly integration, with at least 4–5 years in a leadership role. Prior eVTOL, UAV, helicopter, or aircraft OEM experience strongly preferred.

Education

• Bachelor's/Master's degree in Aerospace, Mechanical, Manufacturing, or Production Engineering
• Additional certifications in Lean Manufacturing, Six Sigma, or Aerospace Quality Systems (AS9100) preferred

Requirements

• Deep hands‑on knowledge of aircraft structures, composites, and metallic assembly techniques
• Experience with manufacturing engineering tools (CAD/CAM, PLM, MES, Six Sigma/Lean)
• Proven track record of taking a program from prototype to production
• Strong leadership, cross-functional collaboration, and stakeholder management
• Excellent problem-solving skills in a fast‑paced, first‑of‑kind product environment
• Familiarity with certification requirements for eVTOL/UAM aircraft is a strong plus