Develop and integrate manufacturing processes for aircraft battery assemblies, electrical systems, wire harnesses, and thermal management. Support DFM/DFA reviews, supplier and tooling validation, SOP and manufacturing instruction creation, MBOM and quality documentation, and prototype-to-serial production scaling. Provide hands-on shop-floor troubleshooting, support technicians, drive root cause analysis, and implement continuous improvements while ensuring compliance with aerospace, IPC, and quality standards.
Job Summary
Dynamic Manufacturing Engineer with specialized expertise in integrating complex electrical systems and high-voltage battery assemblies for next-generation aircraft with Proven track record in bridging the gap between design and the shop floor through robust DFM/DFA strategies, IPC-compliant process development, and real-time troubleshooting. Expertise in scaling battery enclosure assembly, thermal management, and advanced wire harness routing from prototype to serial production in highly regulated aerospace environments.
Role & Responsibilities:
I. Design Integration & Strategy (The "Before the Build" Phase)
- Support DFM/DFA activities during design reviews to ensure the manufacturability and serviceability of complex electrical systems.
- Define wire routing strategies ensuring safety, serviceability, and strict compliance with aerospace standards.
- Collaborate closely with design, quality, and supply chain teams to optimize build flow and reduce cycle time from the outset.
- Work with suppliers and internal teams to validate battery module assembly techniques and specialized tooling.
II. Process Development & Documentation
- Develop and implement manufacturing processes for aircraft battery installation, including enclosure assembly, mounting, thermal management, and electrical interfacing.
- Create and validate build processes for wiring harness routing, terminations, and connector assemblies.
- Develop Standard Operating Procedures (SOPs), Manufacturing Instructions (MIs), and detailed inspection criteria.
- Manage production data, including MBOM (Manufacturing Bill of Materials) preparation, Process Flow Diagrams, Control Plans, and PPAP/FAI documentation.
III. Shop Floor Execution & Troubleshooting
- Provide hands-on support to technicians on the shop floor during both prototype and serial production phases.
- Troubleshoot wiring and battery integration issues in real-time, implementing immediate corrective actions to maintain build schedules.
- Support the creation of harness assembly boards, work instructions, and functional test procedures.
- Drive Root Cause Analysis (RCA) for non-conformances and lead continuous improvement efforts to prevent recurrence.
Technical Skills & Competencies
Electrical Mastery:
- Technical Drawing Fluency: Ability to read wiring harness drawings, circuit diagrams, connector views, and terminal callouts.
- Component Expertise: Deep understanding of wire grades/types, terminal selection, crimp specifications, sealing systems, splice methods, and protection standards (taping/sleeving).
- System Knowledge: Understanding of PCB interfaces, wiring harnesses, and busbar design.
Standards & Quality:
- Industry Standards: Good understanding of IPC/WHMA-A-620 (preferred), IPC-A-600/610, and IPC-7711C/7721C.
- Validation: Proficiency with crimp height charts and pull-force standards.
- Exposure to QMS standards AS9100D is preferred.
- Regulatory Familiarity: Familiarity with international standards (IEC, IS, UL, CE, RoHS, EMC/EMI).
Software & Systems:
- ECAD Tools: Exposure to harness design software (Capital, Zuken) is a significant advantage.
- CATIA Electrical harness module & PLM exposure is preferred
- MS office / Google suite proficiency
Qualifications :
- Bachelor’s degree in Electrical, Electronics or any related field.
- 4+ Years of Experience in ME E&E Integration activities in Aerospace industry preferred.
Work Location: Kelambakkam, Chennai, Tamil Nadu, India.
Job Type: Full-time, Work from office.
- Bachelor’s degree in Electrical, Electronics or any related field.
- 4+ Years of Experience in ME E&E Integration activities in Aerospace industry preferred.
Work Location: Kelambakkam, Chennai, Tamil Nadu, India.
Job Type: Full-time, Work from office.
The ePlane Company Chennai, Tamil Nadu, IND Office
IIT Madras Research Park, Chennai, Tamil Nadu, India, 600036
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