Composite/Metal Bond Process Engineer – Coxsackie, NY – ($90k – $115k) – US Citizen or Green Card Only

Composite/Metal Bond Process Engineer – Coxsackie, NY – ($90k – $115k) – US Citizen or Green Card Only
The Composite/Metal Bond Process Engineer supports various departments (Engineering, Operations, Quality, Manufacturing and Supply Chain) through the development, evaluation, and implementation of processes related to Composites and Metal Bonding processing. Emphasis on knowledge of these processes for aluminum alloys, titanium alloys, and superalloys.

Essential Functions:

• Responsible for developing processes for composite and metal bonding in manufacturing!!!        
• Responsible for interpreting, implementing, and training regarding NADCAP, quality management system including ISO 9001 and AS9100 and customer requirements in the areas of coatings and chemical processing.
•        Address MRB conditions for root cause, and recommend and implement corrective actions.
•        Prepare, revise and oversee internal work instructions and specifications related to area of expertise.
•        Conduct audits in accordance with internal audit programs, host customer and industry audits such as NADCAP and AS9100.  Prepare reports and submit resolutions to audit findings.
•         Develop the internal specification system aligned with external requirements that would increase fidelity of requirements, process control for parts made by internal Operations and by suppliers. Also, review and approve various engineering procedures and specifications.
•         Lead in root cause and corrective action investigation efforts.  Initiate and enable Failure Analysis, create and review failure reports, assist Engineering and customers.
•         Work with Operations, Quality, & Engineering to develop, modify, qualify and troubleshoot various materials, chemical, surfacing, and coating processes.
•         Manage and proactively participate in developing, maintaining, training, and sharing technical knowledge in specialized area(s), remaining up-to-date on current trends and best practices.
•         Support sustainment operations through review of process changes, advising MRB on material and process related discrepancies, and interfacing with customers.
•         Work directly with customers and vendors to understand and formulate their technical requirements and business needs into achievable results
•         Ensure proper maintenance of manufacturing equipment by recommendation of Preventative Maintenance activities and schedules
•          Support New Product Introductions by providing guidance on materials and processes to use for industrialization of new products, participate in efforts to obtain customer process approvals/qualifications.
•         Provide project management, process introduction, and continuous process improvement leadership.
•         Analyze data from production and engineering process runs, qualifying changes or additions to manufacturing toolsets and process flows to drive process performance improvements.
•         Mentor others to cultivate critical process evaluation and best resolution to process issues.
•         Support Research and Development by conducting technology projects, participating in technology reviews, and proposing new technology.
•  Establish and maintain strong and professional collaborative partnerships with other organizations, academic institutions and external partners, as appropriate, in order to leverage best-in-class methods and capabilities.
•         Initiate capital project selection, justification, budgeting, and implementation.
•         Interpret State rules and regulations and assist with flow down of requirements to ensure facility compliance with monthly, quarterly and annual requirements driven by the respective State organizations.
•         Drive safety in all manufacturing and operations processes.
•         Work with EH&S department to ensure the proper handling and management of hazardous waste and compliance with all environmental related activities.
•         Other duties as assigned, including working extended shifts/overtime as required by the business.
•  Travel Required: up to 20%.

Required Skills & Qualifications

• Must have composite metal bonding experience and/or metal bonding experience
• Must have Autoclave experience in manufacturing
• Must have Clean Room Experience!
• Must have experience with alloys
• Demonstrated effectiveness in managing multiple projects, finishing and delivering on commitments
• Ability to develop new specifications, process sheets and control plans for special processes and NDT. Professional in developing and documenting new standard manufacturing processes, as well as interpreting and executing methods outlined by ASTM, AWS, SAE/AMS, ASME, customer, military, and commercial aerospace specifications related to related to composite and metal bonding.
• Customer oriented with a continuous improvement focus
• Experience in aerospace industry working with Materials & Process group preferred.
• Experience with MRB systems and procedures, including but not limited to root cause and corrective action investigations, hands-on experience working with composite materials, processes, fabrication/manufacturing methods, bonding/joining methods, testing, and/or inspection processes preferred.
• Experience reading and interpreting engineering drawings.
• Strong analytical skills and ability to make decisions based on limited data.
• Demonstrated leadership in proactive problem solving and self-directed behavior.
• Can interface effectively with all levels of the organization, suppliers and customers.
•  Ability to develop test plans, run tests, collect data and perform statistical analysis.  Knowledge of Minitab software preferred.
•  Exercise independent judgment in methods, techniques and evaluation criteria for obtaining results.
•  Understands NADCAP, ISO9001, and AS9100 regulatory requirements. Experience with First Articles Inspection (FAI) preferred.
•  Conscientious, organized and meticulous – records must be accurate and well-maintained.
• Strong self-motivation/direction, entrepreneurial mind-set, leadership, and teaming skills. Can manage and direct a  group in short term in the absence of a manager. Lead, train, and guide technicians and operators.
•  Knowledge of Six Sigma/Process Excellence Tools and Methodologies (i.e. DMAIIC, DMADV, Lean, FMEA), including Design of Experiments, capability analysis and sampling statistics and techniques is preferred.
•  Selecting and testing of material chemical processes, both in the development and application of processing methods.
•  Familiar with 3D solid modeling tools (e.g. CATIA) and Geometric Dimensioning and Tolerancing (GD&T).

Required Experience/ Education/ Training/ Certifications

• B.A./B.S. degree in Scientific or Engineering discipline, from an ABET accredited program with minimum (5) years of experience related to materials & processing; preference given to M.S. or Ph.D. advanced degree with (3) years experience (aerospace manufacturing environment preferred).  Equivalent combination of education and experience will be considered.

Licenses, Certifications, etc.  

•        Lean Practitioner, ACE Associate/Practitioner, Six Sigma Greenbelt or higher, or equivalent certification desired.