Repair Development Engineer

Job Description

The Repair Development Engineer is responsible for developing and maintaining repair processes for aero engine components. This person will evaluate, quote, and build work orders for parts needing complex repairs. They will monitor all aspects of the process, including milling, turning, fixturing, welding, heat treatment, EDM, non-destructive testing, assembly, deburr, and more. The individual ensures design features are consistent with functional performance and safety requirements for the aircraft engine installation. The Repair Development Engineer is a hands-on role with heavy involvement in shop floor troubleshooting, and direct communication with major aero OEM customers such as Pratt & Whitney, GE, and Rolls Royce. As new repairs are developed, this person will ensure all hardware, fixtures, and equipment are available and aid in the training of repair personnel to perform ongoing work. The ideal candidate combines hands-on engineering expertise with deep knowledge of aerospace superalloys, machining processes, special processes, and repair approval pathways.

This position sits in Warren, MI and will report to the Repair Engineering Manager.

 Key Responsibilities

• Product and process ownership for complex repair development from inception through industrialization and process maintenance/continuous improvement
• Lead the processing of assigned part families / programs to achieve Quality and Delivery goals. This includes evaluating and building work orders for each individual part, as each part may have different repairable areas.
• Establish operation sequences, work instructions, and best practices to ensure efficient and safe repair procedures are developed.
• Provide technical support and guidance for junior engineers and cross-functional teams (procurement, manufacturing, receiving, quality).
• Evaluate parts and assemblies for repair feasibility, producibility, cost, tooling, and outside processing.
• Conduct and prepare detailed analysis of sample parts to support development of new repair.
• Create CAD models and production drawings using ANSI/ASME Y14.5 GD&T standards. Prepare Manufacturing Operation Sheets (MOS's) to clearly communicate process details to operators.
• Review & approve engineering drawings, work instructions, process specifications, and technical reports.
• Develop processes to ensure work is performed per FAA regulations, customer regulations and Repair Station Manual.
• Coordinates with other departments to develop a unified approach for process improvement of product.
• Interfaces with OEMs, customers, regulatory agencies, and project-related people within the Company.

Job Requirements

• Bachelor's Degree in an Engineering discipline is required
• Preferred – 5+ years’ experience in an aerospace, aeroderivative, or manufacturing environment. Experience with repair and overhaul of aircraft engine components, including complex welded/brazed assemblies; 10+ years of directly relevant experience is highly desired
• Preferred - Advanced understanding of machining approaches (lathe, mill, EDM, etc.), fixturing/workholding, heat treatment, welding, NDT, brazing and/or thermal spray.
• Preferred – Experience with Syteline (Infor Cloudsuite Industrial)
• Preferred – demonstrated experience with cost reduction and efficiency improvement strategies; ability to obtain, analyze, and act on operational data
• Highly desired – FAA DER accreditation or experience working directly with FAA DER
• Familiarity with industry specifications, processes, and materials.
• Experience writing technical publications and repairs, designing alternate repair processes to achieve stated goals.
• Strong problem-solving skills.
• Ability to handle multiple tasks with tight deadlines.
• Strong competencies in leadership, written & verbal communication, emotional intelligence, cultural awareness
• Ability to work effectively in a team environment as well as independently. Shows leadership in integrity and ethical behavior.
• Ability to use technology effectively and efficiently to manage workload.
• Working knowledge of Microsoft Outlook and ability to create documents, reports and briefing materials in Microsoft Office Word, Excel, and PowerPoint.
• Must have unrestricted authorization to work in the USA