Module Manufacturing Engineer

Expleo; Washington (District of Columbia); On-site; USD 66,000 - 110,000; Full time

Benefits offered by this job

Competitive compensation up to $110,0

Comprehensive benefits

Paid holidays and PTO

Career development

Team culture

Job summary

Expleo Group USA is seeking a senior Module Manufacturing Engineer to advance composite manufacturing, aircraft assembly, and process development across prototype to production ramp-up. You will lead process improvements, tooling design collaboration, and documentation efforts to ensure high quality, safe, and efficient production.

The role emphasizes cross-functional collaboration with Design, Quality, and Production teams, along with implementing LEAN methods and manufacturing readiness

Qualifications

• Bachelor's degree in a related technical discipline or equivalent experience in aerospace manufacturing.
• 8+ years of manufacturing engineering experience in aerospace, aviation, defense, or advanced manufacturing.
• Experience developing manufacturing work orders, work instructions, routers, travelers, and production process documentation.
• Strong background in composite manufacturing processes, materials, and fabrication techniques.
• Experience supporting aerospace assembly operations and production environments.
• Experience utilizing MES, ERP systems, and production planning tools.

Responsibilities

• Develop and implement manufacturing processes for composite structures, subassemblies, and final aircraft assembly operations.
• Support prototype, LRIP, and full-rate manufacturing activities.
• Evaluate manufacturing methods and identify opportunities for improvement, cost reduction, and productivity gains.
• Ensure manufacturing processes meet quality, safety, and production requirements.
• Collaborate with Design Engineering to optimize for manufacturability and production efficiency.
• Develop and maintain manufacturing work orders, routers, travelers, and shop floor documentation.
• Translate drawings, CAD models, and specifications into production-ready processes.
• Support engineering change implementation and configuration management activities.
• Provide technical guidance and process documentation to production teams.
• Ensure documentation aligns with customer, regulatory, and aerospace requirements.

Skills

Manufacturing Engineering

Composite Manufacturing

Process Improvement

Manufacturing Documentation

Cross-functional Collaboration

Education

Bachelor's Degree in Manufacturing Engineering

Aerospace Engineering

Tools

MES

ERP systems

Job description

Overview

Module Manufacturing Engineer

Talent Community | Current & Future Client Opportunities

We are growing our network of experienced Module Manufacturing Engineers to support current and upcoming aerospace programs focused on composite manufacturing, aircraft assembly, manufacturing process development, tooling design, production readiness, and operational excellence.

Responsibilities:

Manufacturing Process Development

• Develop and implement manufacturing processes for composite structures, subassemblies, and final aircraft assembly operations.
• Support prototype, low-rate initial production (LRIP), and full-rate manufacturing activities.
• Evaluate manufacturing methods and identify opportunities for process improvement, cost reduction, and productivity enhancement.
• Ensure manufacturing processes meet quality, safety, and production requirements.
• Collaborate with Design Engineering teams to ensure products are optimized for manufacturability and efficient production.
• Support manufacturing readiness activities throughout the product lifecycle.

Work Orders & Manufacturing Documentation

• Create and maintain detailed manufacturing work orders, routers, travelers, and shop floor documentation.
• Develop clear, accurate, and repeatable work instructions for composite fabrication and assembly operations.
• Translate engineering drawings, CAD models, and specifications into production-ready manufacturing processes.
• Support engineering change implementation and configuration management activities.
• Provide technical guidance and process documentation to manufacturing personnel.
• Ensure manufacturing documentation aligns with customer, regulatory, and aerospace requirements.

Composite Manufacturing

• Develop manufacturing methods and procedures for composite layup, bonding, trimming, curing, and assembly operations.
• Support production teams in executing composite fabrication activities while maintaining quality and schedule objectives.
• Evaluate manufacturing challenges and implement corrective actions to improve process capability and product quality.
• Partner with Quality teams to resolve nonconformances and improve first-pass yield performance.
• Assist in transitioning products from development and prototype phases into production environments.
• Support continuous improvement of composite manufacturing processes and best practices.

Aerospace Assembly Processes

• Define, develop, and optimize aircraft assembly processes for structures, modules, and integrated systems.
• Support assembly sequencing, work package development, and production planning activities.
• Participate in manufacturing readiness reviews and production build planning efforts.
• Collaborate with production teams to troubleshoot assembly issues and improve production flow.
• Drive process standardization and implementation of assembly best practices.
• Support production ramp-up activities and operational performance improvements.

Tooling & Fixture Design

• Design and develop manufacturing tooling, assembly fixtures, and composite layup aids.
• Support tooling requirements throughout product development and the production lifecycle.
• Evaluate tooling effectiveness and implement enhancements to improve quality, safety, and efficiency.
• Collaborate with Manufacturing, Design, and Quality teams to ensure tooling solutions support production objectives.
• Manage tooling modifications, maintenance requirements, and continuous improvement initiatives.
• Support tooling validation and production readiness assessments.

Continuous Improvement & Risk Reduction

• Lead manufacturing process improvement initiatives focused on quality, cost, delivery, and operational efficiency.
• Apply Lean Manufacturing principles to reduce waste and improve shop floor performance.
• Participate in root cause investigations and corrective action implementation activities.
• Support process validation efforts and manufacturing readiness assessments.
• Contribute to production KPI development, reporting, and performance monitoring.
• Drive continuous improvement initiatives that support operational excellence and manufacturing maturity.

Qualifications:

• Bachelor's Degree in Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering, Industrial Engineering, or a related technical discipline.
• Equivalent combination of education and significant aerospace manufacturing experience may be considered.
• 8+ years of manufacturing engineering experience within aerospace, aviation, defense, or advanced manufacturing environments.
• Experience developing manufacturing work orders, work instructions, routers, travelers, and production process documentation.
• Strong background in composite manufacturing processes, materials, and fabrication techniques.
• Experience supporting aerospace assembly operations and production environments.
• Experience designing manufacturing tooling, assembly fixtures, and composite layup tooling.
• Ability to interpret engineering drawings, specifications, and 3D CAD models.
• Strong process improvement, troubleshooting, and problem-solving capabilities.
• Excellent communication and cross-functional collaboration skills.
• Ability to work effectively in a fast-paced aerospace manufacturing environment.
• Experience supporting UAV, UAS, or autonomous aircraft programs.
• Experience conducting or supporting PFMEA (Process Failure Mode and Effects Analysis) activities.
• Knowledge of Lean Manufacturing and Continuous Improvement methodologies.
• Familiarity with AS9100 and aerospace quality management systems.
• Experience supporting prototype development, low-rate production, and production ramp-up efforts.
• Knowledge of composite curing, bonding, trimming, and structural assembly processes.
• Experience utilizing Manufacturing Execution Systems (MES), ERP systems, and production planning tools.
• Understanding of aircraft structures, tooling validation, and manufacturing readiness requirements.
• Experience supporting Airbus aerospace programs or advanced aerospace manufacturing environments.

What We Offer

At Expleo Group USA, we value expertise, innovation, and collaboration. By joining our client's team, you'll support cutting-edge aerospace manufacturing programs while working alongside talented professionals in a highly collaborative and technically engaging environment.

• Competitive Compensation – Up to $110,000 annually or $53/hourly. Please note that the compensation range displayed is a generalized range for pipelining purposes and may not reflect the final range for a specific role. Final compensation will be determined based on the role, skill alignment, years of experience, and fair, market-based rates by geography.
• Comprehensive Benefits for You and Your Dependents – Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short/Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with matching.
• Paid Holidays and Paid Time Off
• Career Development and Advancement – Expleo is a global company operating in 29 countries with a strong focus on professional development.
• Strong Team Culture – Collaborate with experienced professionals who value innovation, operational excellence, continuous improvement, and teamwork.

This position may require access to information subject to U.S. export control regulations (e.g., ITAR/EAR). Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to "U.S. Persons," including U.S. citizens, lawful permanent residents (green card holders), and individuals granted refugee or asylee status.

Expleo is a trusted partner for end-to-end, integrated engineering, quality services, and management consulting for digital transformation. We are a talent incubator. The time you spend at Expleo will turbocharge your career, allowing you to work on complex technical challenges, expand your skills, and participate in inspiring multidisciplinary collaborations. Whether working on advanced unmanned aircraft systems, next-generation aerospace manufacturing, or innovative engineering solutions, you'll have the opportunity to become a bolder version of yourself. Let's change the game together.

Expleo is an equal opportunity employer. We are committed to non-discrimination in all stages of the recruitment process, ensuring fair and unbiased hiring practices. We evaluate qualified applicants without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, or any other protected characteristic under applicable laws.