Overview
The Sheet Metal Engineering Program Manager serves as a key member of the engineering team and is responsible for leading the successful execution of new and existing sheet metal products throughout the entire manufacturing lifecycle. Working closely with Engineering, Manufacturing, Quality, Supply Chain, Planning, Tooling, and Operations, this position ensures all technical, quality, and customer requirements are met while driving projects from concept through production implementation. The role is responsible for managing program schedules, technical risks, manufacturing readiness, tooling requirements, process development, and continuous improvement initiatives to ensure repeatable, efficient, and compliant production processes.
Responsibilities
Essential Duties and Responsibilities
- Lead and manage new sheet metal product introductions and existing production programs from quotation through production release.
- Serve as the primary engineering focal point for program execution, customer requirements, technical issues, and manufacturing readiness activities.
- Coordinate cross-functional teams to ensure engineering, quality, tooling, planning, supply chain, and production objectives are achieved.
- Develop and manage project timelines, milestones, deliverables, and risk mitigation plans.
- Review engineering drawings, 3D models, specifications, customer requirements, and manufacturing standards to ensure producibility and compliance.
- Drive Design for Manufacturability (DFM) reviews and recommend improvements to improve quality, reduce cost, and increase production efficiency.
- Develop and implement manufacturing processes for complex sheet metal assemblies and components, including cutting, forming, machining, welding, assembly, and finishing operations.
- Evaluate and define tooling, fixtures, gages, and equipment requirements necessary to support production and inspection activities.
- Review and validate routes, work instructions, Bills of Material (BOMs), Product Configuration Control Information (PCCI), and manufacturing documentation.
- Ensure production planning accurately reflects validated processes capable of supporting repeatable manufacturing.
- Coordinate prototype, first article, qualification, and production builds while ensuring lessons learned are incorporated into standard processes.
- Support quoting activities through technical reviews, labor estimates, tooling assessments, and manufacturing feasibility evaluations.
- Prepare engineering cost estimates, status reports, and program updates by collecting, analyzing, and summarizing project data.
- Lead resolution of manufacturing, quality, and technical issues through root cause analysis and corrective actions.
- Work closely with Quality Assurance and Document Control regarding revision changes, engineering changes, customer requirements, and corrective action implementation.
- Monitor program performance, identify potential risks, and implement corrective actions to maintain schedule, quality, and cost objectives.
- Participate in continuous improvement initiatives focused on process capability, efficiency, quality, and manufacturing throughput.
- Maintain compliance with company policies, customer requirements, aerospace standards, and applicable regulatory requirements.
- Demonstrate the authority to stop production when quality, safety, or technical concerns warrant immediate action.
Qualifications
- Minimum 5 years of engineering or manufacturing experience in sheet metal fabrication, aerospace manufacturing, or related industries.
- Prior project or program management experience preferred.
- Experience supporting new product introduction (NPI), production transitions, and manufacturing process development.
- Strong understanding of sheet metal fabrication processes including laser cutting, punching, bending, hydroforming, machining, welding, assembly, and finishing.
- Ability to interpret and apply engineering drawings, 3D models, GD&T, specifications, and customer requirements.
- Experience with aerospace manufacturing requirements and specifications.
- Proficiency in CATIA V5 or similar CAD software.
- Knowledge of MRP/ERP systems and manufacturing planning processes.
- Experience with FAI, RCCA, process validation, and configuration management.
- Understanding of tooling design, fixture development, and manufacturing process optimization.
- Strong project management, organizational, and time-management skills.
- Excellent written and verbal communication skills.
- Ability to lead cross-functional teams and manage multiple projects simultaneously.
- Lean Manufacturing and continuous improvement experience preferred.
