Engine Test Technician

Essential Duties & Responsibilities

• Conduct daily production acceptance testing of turbojet engines.
  • Perform pre-test inspections and verify engine configuration.
  • Install engines into production test cells.
  • Configure instrumentation and data acquisition equipment.
  • Execute approved production test procedures.
  • Monitor engine operating parameters throughout all phases of testing.
  • Perform engine startup, operational monitoring, shutdown, and post-test inspections.
  • Verify engine performance against established acceptance criteria.
  • Identify nonconforming hardware and coordinate disposition.
  • Prepare accepted engines for shipment or subsequent manufacturing operations.
• Serve as the owner of assigned production test cell(s).
  • Maintain continuous operational readiness of production test cells.
  • Maintain all fixtures, adapters, tooling, instrumentation, and support equipment.
  • Verify calibration status of sensors and instrumentation.
  • Clock in calibration activities with Quality.
  • Coordinate calibration activities.
  • Maintain spare sensors, thermocouples, pressure transducers, cables, and instrumentation hardware.
  • Clock in preventative maintenance activities.
  • Maintain consumable inventory including filters, hoses, fittings, lubricants, and fuel system components.
  • Maintain excellent housekeeping utilizing 5S principles.
  • Identify equipment reliability issues.
  • Recommend equipment upgrades and process improvements.
  • Verify equipment readiness before each production shift.
• Data Collection & Documentation
  • Record engine performance data accurately.
  • Ensure complete traceability of all engine serial numbers.
  • Document engine configuration prior to testing.
  • Record all production acceptance results.
  • Upload electronic test records.
  • Document discrepancies and anomalies.
  • Support development of production acceptance reports.
  • Ensure complete and accurate test documentation before engine release.
• Diagnostics & Troubleshooting
  • Troubleshoot engine starting issues.
  • Troubleshoot engine performance anomalies.
  • Troubleshoot instrumentation failures.
  • Support vibration investigations.
  • Aid in engine balancing activities.
  • Support root cause investigations.
  • Aid in corrective actions and retesting.
  • Escalate engineering-related issues to the Test Engineer.
• Development & Engineering Support
  • Support engineering testing activities including: Development testing, Qualification testing, Prototype evaluations, Design verification testing, Customer witness testing, Experimental hardware evaluations, Instrumentation installation, Engine teardown and post-test inspections, Test fixture validation.
• Manufacturing Support
  • Partner with Manufacturing by: Providing feedback regarding assembly quality, Identifying recurring production issues, Supporting production launch activities, Improving first-pass yield, Assisting with production bottleneck reduction, Supporting continuous improvement initiatives, Assisting with standardized work instructions, Supporting training of Engine Assembly Technicians on test-related requirements.
• Continuous Improvement
  • Recommend improvements to production test procedures.
  • Improve test repeatability.
  • Improve production throughput.
  • Reduce test cycle time.
  • Reduce first-pass failures.
  • Improve test cell uptime.
  • Support Lean Manufacturing initiatives.
  • Serve as Kaizen event facilitator.
  • Capture lessons learned.
  • Improve overall production test capability.
• Safety, Quality & Compliance
  • Operate all equipment safely.
  • Follow all engine test safety procedures.
  • Ensure compliance with AS9100 requirements.
  • Follow Quality Management System procedures.
  • Maintain safe operating conditions.
  • Utilize required PPE.
  • Support customer audits.
  • Support regulatory audits.
  • Promote a culture of safety, accountability, and continuous improvement.

KEY PERFORMANCE INDICATORS (KPIs)

• Production Performance: Daily production schedule attainment, Production throughput, On-time engine testing, First-pass test yield, Engine acceptance rate, Test cycle time.
• Test Cell Performance: Test cell uptime, Equipment availability, Preventative maintenance completion, Calibration compliance, Test fixture readiness, Equipment reliability.
• Quality & Data Integrity: Accurate production test documentation, Engine traceability, Configuration verification, Same-shift completion of test reports, Data accuracy, Discrepancy reporting.
• Continuous Improvement: Reduced test cycle time, Improved first-pass acceptance, Improved equipment uptime, Reduced production bottlenecks, Improved standard work, Support of Lean and 5S initiatives.

DECISION AUTHORITY

• Stop testing for unsafe conditions.
• Stop testing due to equipment malfunction.
• Reject engines that fail acceptance criteria.
• Escalate engineering issues to the Test Engineer.
• Request Manufacturing support.
• Recommend process improvements.
• Recommend equipment repairs.
• Delay engine release until all production acceptance requirements have been satisfied.

CROSS-FUNCTIONAL INTERFACE

• Works closely with: Manufacturing Manager, Test Engineer, Manufacturing Engineer, Engineering Technician, Product Engineering, Quality Engineering, Quality Inspectors, Engine Assembly Technicians, Supply Chain, Program Management, Facilities & Maintenance.