Dy Manager-Manufatcuring Engineering

Aerospace Fasteners Development

Position Requirement: Responsible for end-to-end development of aerospace fasteners, from RFQ and feasibility assessment through product/process development, tooling and trials, sample validation, FAI/PPAP, customer approval and transfer to serial production, ensuring compliance with applicable aerospace standards, customer specifications, quality, statutory, legal and regulatory requirements.

Educational Qualification

• Bachelors Degree in Mechanical / Production / Manufacturing / Aerospace Engineering.
• Diploma holders with extensive relevant experience may also be considered.

Experience

• 7-15 years of relevant experience in aerospace fastener/product development, preferably in aerospace fastener manufacturing.
• Strong experience in cold forging, warm forging, hot forging, CNC machining, thread rolling, heat treatment and surface treatment.
• Proven experience in end-to-end NPD from feasibility to customer approval.
• Experience in aerospace customer development, FAI/PPAP and technical documentation.

Key Responsibilities

• Review customer RFQs, drawings, specifications and applicable standards and conduct technical/manufacturing feasibility studies.
• Identify CTQs, special characteristics, manufacturing risks and appropriate process routes for aerospace fasteners.
• Develop and optimize forging, machining, thread rolling, heat treatment and surface-treatment processes to meet dimensional, metallurgical and functional requirements.
• Develop and coordinate process flow, operation sequence, tooling, dies, fixtures, gauges and manufacturing methods.
• Plan and execute prototype, sample and process trials, analyse results and implement necessary process improvements.
• Ensure complete material, process, inspection, testing and product traceability throughout the development cycle.
• Coordinate product validation, inspection and testing, review results and ensure closure of failures/non-conformities.
• Lead preparation and submission of FAI/PPAP and NPD documentation, including Process Flow, PFMEA, Control Plan and related technical records.
• Coordinate with customers on technical clarifications, development reviews, deviations, observations and approval requirements and drive timely closure to obtain customer approval.
• Maintain development history, configuration/revision control and technical records and support customer, certification and third-party audits.
• Lead structured problem solving using 8D, 5-Why, Fishbone, FMEA, SPC and other quality tools to resolve development and process issues.
• Coordinate with Production, Quality, Tooling, SCM, Purchase, Manufacturing and other cross-functional teams to achieve development milestones.
• Lead development review meetings, monitor action plans and ensure on-time completion of NPD activities.
• Support successful transfer of approved products from development to serial production.

Technical Competencies

• Knowledge on AUTO CAD/ SOLID WORKS
• Aerospace fastener manufacturing and NPD.
• Forging process and tooling.
• CNC machining and thread rolling.
• Aerospace drawing interpretation and GDT.
• Material specifications and metallurgy.
• Heat treatment and surface treatment/plating.
• Aerospace standards and customer specifications.
• APQP, PFMEA, Process Flow, Control Plan and FAI/PPAP.
• Root-cause analysis, problem solving and process capability.
• Technical documentation, customer communication and product traceability.

Preferred Standards / Knowledge

Working knowledge of applicable NAS, MS, AS, SAE, ASTM and customer-specific aerospace standards, along with applicable quality and regulatory requirements.

Knowledge of AS9100, NADCAP and aerospace special-process requirements will be an added advantage.

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