JUNIOR ENGINEER - MASKING (SPECIAL PROCESS)

Sansera Engineering Limited

PRIME FUNCTION

To manage and control masking activities associated with aerospace surface treatment processes, ensuring accurate masking application, protection of specified areas, process compliance, and achievement of customer, drawing, and aerospace quality requirements.

Job Description / Responsibilities

• Plan, execute, and monitor masking activities for aerospace components prior to surface treatment processes.
• Interpret engineering drawings, masking drawings, specifications, and customer requirements to identify areas requiring protection.
• Develop and implement suitable masking methods for various surface treatment processes.
• Ensure correct masking of surfaces, holes, threads, contact areas, and other critical features as specified.
• Select appropriate masking materials such as tapes, plugs, caps, fixtures, lacquers, and protective materials.
• Ensure proper preparation, cleaning, application, and removal of masking materials.
• Monitor masking quality to prevent over-coating, under-coating, contamination, and unwanted surface treatment.
• Establish and maintain standardized masking methods, work instructions, and process parameters.
• Coordinate with Surface Treatment, Production, Quality, Engineering, and Planning teams for smooth process execution.
• Support new product development, process trials, FAI, and process validation activities.
• Identify masking-related defects and conduct root cause analysis for recurring issues.
• Implement corrective and preventive actions to reduce rejection, rework, and process variation.
• Monitor masking process efficiency, material consumption, cycle time, and productivity.
• Develop and improve masking fixtures, templates, and application methods wherever required.
• Ensure traceability and proper documentation of masking activities and process records.
• Ensure compliance with aerospace quality standards, customer specifications, and approved process procedures.
• Support internal, customer, and certification audits related to special processes.
• Train and guide masking operators on standard procedures, quality requirements, and safe handling practices.
• Drive 5S, Kaizen, process improvement, and cost-reduction initiatives within the masking area.

Ensure proper handling, storage, and disposal of masking materials and chemicals as per safety and environmental requirements.

AUTHORITY

• Approve masking methods and process settings within the defined scope.
• Stop or hold the process when masking does not meet drawing or quality requirements.
• Reject or segregate improperly masked components.
• Recommend changes to masking materials, methods, fixtures, and process parameters.
• Initiate corrective and preventive actions for masking-related quality issues.
• Coordinate with Quality and Surface Treatment teams for process acceptance and issue resolution.
• Escalate critical process deviations and customer-related concerns to the reporting manager.

JOB SPECIFICATION / COMPETENCY

Educational Qualification

• Diploma in Mechanical, Production, Chemical, Metallurgy, Aerospace Engineering, or related discipline.
• Certification or training in Aerospace Special Processes is preferred.

Experience

• 3-7 years of experience in masking, surface treatment, plating, anodizing, chemical processing, or aerospace special processes.
• Experience in aerospace or precision manufacturing is preferred.

Technical Competencies

• Strong knowledge of masking techniques used in aerospace surface treatment processes.
• Understanding of anodizing, plating, chemical conversion coating, passivation, painting, and other surface treatment processes.
• Ability to read engineering drawings, GD&T, specifications, and masking requirements.
• Knowledge of masking materials, tapes, plugs, caps, lacquers, fixtures, and application techniques.
• Understanding of surface treatment process requirements and critical characteristics.
• Knowledge of aerospace quality requirements and special process controls.
• Familiarity with FAI / AS9102, PFMEA, Control Plan, SOPs, and process documentation.
• Knowledge of root cause analysis, 8D, 5 Why, and corrective action methodologies.
• Understanding of chemical handling, PPE, EHS, and environmental requirements.
• Basic knowledge of SAP / ERP and quality documentation systems.

Behavioral Competencies

• Strong attention to detail and precision.
• Good analytical and problem-solving skills.
• Strong communication and cross-functional coordination.
• Leadership and team-handling capability.
• Ability to work under pressure and meet production schedules.
• Proactive approach towards quality and process improvement.
• Strong ownership and accountability.

PERFORMANCE MEASURES

• Masking First Pass Yield (FPY).
• Reduction in masking-related rejection and rework.
• Accuracy of masking as per drawing and customer specifications.
• Reduction in surface treatment defects caused by improper masking.
• On-time completion of masking activities as per production schedule.
• Improvement in masking cycle time and productivity.
• Reduction in masking material consumption and process cost.
• Successful implementation of new masking methods and fixtures.
• Timely closure of masking-related NCRs, customer complaints, and audit findings.
• Compliance with aerospace special process requirements.
• Effectiveness of operator training and process standardization.
• 5S, safety, chemical handling, and environmental compliance.
• Contribution to Kaizen and continuous improvement initiatives.

Skills Competencies

Attention to details

Collaboration and Team building

Communicating Effectively

Delivering High Quality Work

Adapting to Change