Job Description Summary

Plan the day-to-day execution and technical support for the introduction of Special processes for new product development and existing process. Support efforts to consistently improve product and process quality. This role is recognized as a key manufacturing technology specialist within their organization. Interface with global counterparts to achieve program goals and integrate global activities when necessary.
Functions with some autonomy but guided by established policies or review of end results.
The job allows modification of procedures and practices covering work as long as the end results meet standards of acceptability.

Job Description

Primary responsibilities include:

• As a Special Process Engineer, Lead process development, prototype builds, new product development, managing cost out programs related to special processes.
• Responsible for Special processes including Heat treatment, Brazing, Honeycomb brazing & Air flow for materials like Inconel, Stainless steel, Rene, Hastelloy, GTD222 etc.
• Identifying customer requirements and its flow down through work instructions, Routers and procedures.
• Define requirements for production capacity, initial acceptance quality, estimating cycle time, manufacturing test equipment, and documentation for your product line.
• Verification of process control parameters, inspection records -review and sign off, trouble shooting and problem solving related to process and equipment.
• Daily monitoring of air flow process equipment, and process control verification, trend analysis etc.
• Daily monitoring of vacuum furnace operation, maintenance checks of vacuum furnace and maintenance logs and related documentation
• Should know braze alloy application process and can select between different alloy forms like foil/powder/paste/wire/tape etc. as per the process requirement.
• Qualification and Training of operators on the special processes and related equipment. Maintaining skill matrix and preparing their skill enhancement plan for the year.
• Experience in preparing calibration requirement and reviewing the calibration certificates of Furnace and air flow equipment's and gauges. Co-ordination with QA and calibration team for the same and ensuring process and quality compliance.
• Having experience on TUS and SAT calibration
• Experience on preparing NADCAP audit documentation, compliance to customer specifications for Heat treatment and Air flow.
• Control of consumables and Implementing ideas for cost reduction
• Root cause analysis for the process defects and implementation of the corrective actions
• Preparation of Standard Work, EHSRA, Aspect impact, Heat Map and SOD and periodic review
• Preparation of PFMEA, RPN reduction plan and periodic review.
• Identify and drive various cost out projects for the COE.
• Responsible for driving ECN/PCN/CID's.
• Proficient in making Manufacturing Operations Sheet for the special processes for which he is responsible.
• Knowledge of PYROMETRY (AMS 2750) is must. Able to establish and demonstrate linkage of every related process requirement of pyrometry and drawing in SOP, router, procedures and Checklists.
• Support Transfer projects between sites and other internal/external sites
• Work with global teams and customers during NPI and as well as Serial production phase.
• Work with MFG Operations to simplify production lines, improve productivity.

Qualifications/Requirements:

• Bachelor's degree in engineering, Preferably Metallurgy and Material science Engineering OR Mechanical Engineering
• Minimum 7 years of relevant experience in a Special processes like vacuum heat treatment, brazing and air flow testing.
• Preferred if having experience on Aviation parts and knowledge of AS 9100 requirements.

Desired Characteristics:

• Ability to identify/track metrics and drive continuous improvement.
• Proficient in reading drawing, specifications and suggesting the suitable special process parameters.
• Should be having knowledge of preparing furnace recipes and air flow testing programs.
• Knowledge of different problem-solving methodologies used in Special processes.
• Excellent interpersonal skills, ability to clearly communicate to internal/external customers and suppliers.
• Ability to interface with varied levels from Operators to Plant Management.
• Expertise in Estimation/Costing and Economics of Heat treatment & Air flow
• Experience in Assembly processes.
• Added advantages of having experience on advanced mfg. processes like EDM, EBW etc
• Humble: respectful, receptive, agile, eager to learn
• Transparent: shares critical information, speaks with candor, contributes constructively
• Focused: quick learner, strategically prioritizes work, committed
• Leadership ability: strong communicator, decision-maker, collaborative
• Problem solver: analytical-minded, challenges existing processes, critical thinker

Additional Job Description

Additional Information

Compensation Grade

LPB2

Relocation Assistance Provided: Yes