Head- Prototype Manufacturing process & Assembly Integration

The ePlane Company; Chennai District; On-site; INR 3,000,000 - 5,000,000; Full time

Job summary

The ePlane Company seeks a Head of eVTOL Prototyping, Manufacturing Process & Assembly Integration to lead end-to-end transformation of aircraft design into flight-ready prototypes and scalable production.

This role owns prototype build strategy, manufacturing process development, tooling/fixture design, and full-aircraft integration, ensuring the platform moves from concept to certified, production-ready aircraft in a fast-paced, aerospace environment.

Qualifications

• Bachelor's or Master's degree in aerospace or related engineering.
• Lean, Six Sigma, or AS9100 certification preferred.
• Extensive leadership in aerospace prototyping and assembly.

Responsibilities

• Lead strategy and execution of full-scale and sub-scale eVTOL prototype builds.
• Translate CAD/PLM outputs into manufacturable prototype packages.
• Drive rapid iteration between design, test, and manufacturing teams.
• Design and industrialize manufacturing processes for airframe structures and subsystems.
• Own final assembly line design, sequencing, and build strategy.
• Ensure compliance with aerospace quality standards and DGCA regulations.

Skills

Leadership

Cross-functional collaboration

DFMA

Lean manufacturing

Kaizen

Automation

MES/PLM integration

Quality systems

Education

Bachelor's/Master's degree in Aerospace/Mechanical/Manufacturing/Production Engineering

Lean / Six Sigma / AS9100 certification

Tools

CAD/CAM

PLM

MES

Six Sigma tools

Job description

Job Summary

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

1. Prototyping Leadership

• 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

6. Continuous Improvement & Scale-up

• 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