Johnson Service Group (IL)
Job Description
We are seeking an experienced Senior Composite Manufacturing Engineer to lead the development, optimization, and implementation of advanced composite manufacturing processes for high-performance aerospace structures. The ideal candidate will bring over a decade of hands-on experience in aerospace composites, with a strong background in production support for major aircraft programs such as the Boeing 787 or Airbus A350.
Key Responsibilities:
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We are seeking an experienced Senior Composite Manufacturing Engineer to lead the development, optimization, and implementation of advanced composite manufacturing processes for high-performance aerospace structures. The ideal candidate will bring over a decade of hands-on experience in aerospace composites, with a strong background in production support for major aircraft programs such as the Boeing 787 or Airbus A350.
Key Responsibilities:
- Design, develop, and optimize composite manufacturing processes including layup, curing, trimming, bonding, and assembly for structural aerospace components.
- Collaborate with multidisciplinary teams-including Design, Quality, and Production-to ensure manufacturability, structural integrity, and compliance with aerospace industry standards (e.g., FAA, AS9100).
- Author detailed manufacturing work instructions and process documentation to guide composite production and ensure consistency across operations.
- Lead continuous improvement initiatives by applying lean manufacturing principles to increase efficiency, reduce cycle time, and eliminate process bottlenecks.
- Conduct Process Failure Mode and Effects Analysis (PFMEA) to proactively identify and mitigate manufacturing risks.
- Develop and implement innovative tooling solutions and automation strategies to support scalable, cost-effective production.
- Oversee first article inspections (FAIs), material testing, and root cause analysis related to composite manufacturing issues.
- Support the transition from prototype builds to high-volume production, ensuring repeatability and process stability.
- Work with supply chain and procurement teams to source advanced composite materials and specialized equipment.
- Ensure strict adherence to quality and safety protocols, including Foreign Object Debris (FOD) prevention and environmental compliance.
- Contribute to the creation of composite-specific documentation, including process control plans, technical manuals, and operator training materials.
- Stay abreast of emerging composite technologies and actively contribute to innovation in aerospace manufacturing.
- Bachelor's degree in Manufacturing, Mechanical, or Aerospace Engineering (or related discipline).
- 10+ years of experience in composite manufacturing within the aerospace industry.
- In-depth knowledge of composite materials (e.g., carbon fiber, fiberglass) and resin systems.
- Demonstrated experience in high-performance aerospace programs and familiarity with large composite structures.
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