Process Engineer/Assembly Leak Test

Overview

Aerostar Manufacturing is seeking an experienced Assembly / Leak Test / Process Engineer to support the development, validation, and continuous improvement of manufacturing assembly processes and leak testing systems for automotive, aerospace, and industrial products.

This role is responsible for supporting new product launches, optimizing manufacturing processes, improving product quality, reducing cycle time, and increasing equipment reliability. The successful candidate will work closely with Engineering, Quality, Manufacturing, Maintenance, Automation, Tooling, and customers to develop robust, repeatable manufacturing processes that meet customer and regulatory requirements.

Key Responsibilities:

Assembly Process Engineering

• Develop and implement assembly processes for new and existing products.
• Design and optimize manufacturing methods, tooling, fixtures, and poka-yoke solutions.
• Create work instructions, SOPs, process flow diagrams, and manufacturing documentation.
• Support Design for Manufacturability (DFM) reviews.
• Coordinate pilot builds and process validation activities.
• Implement engineering changes and support production launches.

Leak Test Process Engineering

• Develop, validate, and optimize pressure decay leak test processes.
• Establish leak test parameters and acceptance criteria.
• Validate leak testing systems using certified master leaks and calibration standards.
• Troubleshoot false rejects, false accepts, and process variation.
• Analyze leak test data to improve process capability and reliability

Manufacturing & Continuous Improvement

• Provide daily engineering support to production.
• Investigate manufacturing issues impacting quality, throughput, and downtime.
• Lead Lean Manufacturing and continuous improvement initiatives.
• Perform time studies, line balancing, and cycle time analysis.
• Improve Overall Equipment Effectiveness (OEE).
• Reduce scrap, downtime, and rework.
• Support APQP, PPAP, PFMEA, Control Plans, and Process Flow development.
• Perform Root Cause Analysis using 8D, 5 Why, Fishbone, and Pareto methodologies.
• Support internal, customer, and certification audits.
• Partner with Product Engineering, Quality, Manufacturing, Maintenance, Automation, and suppliers.
• Support equipment procurement, installation, commissioning, and validation.
• Train production personnel on new processes and equipment.
• Participate in design reviews and new product launch activities.

Qualifications:

• Bachelor’s degree in mechanical engineering, Manufacturing Engineering, Industrial Engineering, or a related engineering discipline.
• 3–7 years of experience in manufacturing engineering, process engineering, assembly engineering, or leak test engineering.
• Experience developing automated assembly processes and leak testing systems.
• Strong understanding of pressure decay leak testing principles and equipment.
• Knowledge of APQP, PPAP, PFMEA, MSA, SPC, Control Plans, and Process Flow Diagrams.
• Experience interpreting engineering drawings and GD&T.
• Familiarity with PLC-controlled equipment, automation systems, torque tools, and industrial robotics is preferred.
• Working knowledge of Lean Manufacturing, Six Sigma, and continuous improvement methodologies.
• Strong analytical, troubleshooting, communication, and project management skills.
• Proficiency with Microsoft Office and manufacturing data analysis tools.

Preferred Qualifications

• Six Sigma Green Belt or higher certification.
• Experience in automotive, aerospace, or high-volume manufacturing environments.
• Familiarity with IATF 16949, AS9100, and ISO 9001 quality management systems.
• Experience supporting new equipment procurement, installation, validation, and production launch.
• Knowledge of vision systems, barcode traceability, torque monitoring, and automated inspection technologies.

Benefits:

• 401(k) matching
• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Referral program
• Tuition reimbursement
• Vision insurance

Education:

• Bachelor's (Required)

Experience:

• Manufacturing engineering: 5 years (Required)
• Leak test Engineering: 5 years (Required)
• GD&T: 3 years (Required)
• Test automation: 3 years (Required)
• APQP: 3 years (Required)
• Lean manufacturing: 3 years (Required)

Work Location: In person