Head of Operations – Aerostructure Assembly

Head of Operations – Aerostructure Assembly

Designation: Head of Operations

Reporting To: COO / Business Head

 Job Purpose

To lead and manage end-to-end operations of the Aerostructure Assembly Program, covering industrialization, facility and tooling readiness, manpower planning, First Article Inspection (FAI), and serial production. The role is responsible for ensuring operational excellence, product quality, on-time delivery, cost control, and compliance with aerospace quality standards and customer requirements.

 Industry: Areospace

Key Responsibilities:

Aerostructure Assembly Operations

• Lead aircraft structural assembly operations, including subassembly, major assembly, and final assembly, as applicable to the program.
• Manage assembly activities involving aircraft fuselage, wing structures, tail structures, frames, panels, brackets, and other structural components.
• Ensure adherence to approved drawings, engineering specifications, assembly sequences, process sheets, and work instructions.
• Monitor production output, cycle time, productivity, rework, and delivery performance.
• Establish effective shop-floor controls to ensure safe, efficient, and quality-driven production.

 Industrialization and FAI

• Lead industrialization activities from technical data review to production readiness and serial manufacturing.
• Coordinate with Engineering and Quality teams to establish assembly processes, work instructions, inspection plans, and manufacturing documentation.
• Ensure readiness of assembly jigs, fixtures, drill templates, special tools, gauges, and inspection equipment.
• Plan and lead FAI preparation and execution in accordance with applicable customer requirements and AS9102, where applicable.
• Coordinate closure of FAI observations and non-conformances to achieve customer approval for production.

Production Planning and Execution

• Develop and implement production plans, capacity assessments, manpower deployment, and shift schedules.
• Ensure achievement of production targets, customer delivery schedules, and program milestones.
• Identify bottlenecks and implement corrective actions to improve throughput and operational efficiency.
• Monitor daily production performance and conduct regular reviews with cross-functional teams.
• Ensure effective material kitting, work-in-progress control, tool availability, and prevention of foreign object debris (FOD).

Manpower Management and Development

• Plan manpower requirements for assembly engineers, supervisors, skilled assemblers, riveting technicians, and supporting functions.
• Lead recruitment, training, competency assessment, and qualification of assembly personnel.
• Establish clear roles, responsibilities, performance objectives, and productivity standards.
• Build a technically competent workforce capable of meeting aerospace manufacturing and assembly requirements.

Quality and Customer Coordination

• Ensure compliance with AS9100, applicable aerospace customer requirements, and approved manufacturing processes.
• Work closely with Quality Assurance to ensure product conformity, traceability, inspection readiness, and documentation compliance.
• Coordinate with customer representatives during technical reviews, inspections, FAI, and production progress meetings.
• Drive root-cause analysis, corrective actions, continuous improvement, and reduction of rework and rejection.
• Ensure strict adherence to configuration control, tool control, and FOD prevention practices.

Tooling, Infrastructure, and Resource Management

• Ensure readiness of the assembly facility, utilities, workstations, tools, fixtures, and inspection infrastructure.
• Coordinate with Tooling, Engineering, Procurement, and Supply Chain teams to ensure timely availability of resources.
• Identify and resolve technical and operational constraints affecting assembly progress.
• Support CAPEX and OPEX planning, cost monitoring, and effective utilization of manpower and infrastructure.

Continuous Improvement

• Implement Lean Manufacturing, 5S, visual management, and standard operating practices.
• Drive improvements in labour productivity, assembly cycle time, first-pass yield, and cost efficiency.
• Establish performance dashboards and periodic reviews to monitor operational KPIs.
• Promote a culture of quality, safety, accountability, and continuous improvement.

Educational Qualification:

• Essential: B.E. / B.Tech in Mechanical Engineering, Aeronautical Engineering, Aerospace Engineering, or Production Engineering.
• Candidates must possess a strong technical foundation relevant to aircraft structural assembly and manufacturing.

Experience Required:

• 15–18 years of overall experience in the aerospace industry.
• Significant hands-on and leadership experience in aircraft structural assembly and aerostructure manufacturing.
• Proven experience managing assembly operations, preferably covering industrialization, FAI, and serial production.
• Practical knowledge of aircraft structural assembly processes, including drilling, reaming, countersinking, riveting, fastening, shimming, sealing, and dimensional alignment, as applicable.
• Experience in assembly jig and fixture planning, tooling readiness, process planning, and production line establishment.
• Experience in production planning, manpower management, capacity utilization, quality control, and customer coordination.
• Working knowledge of AS9100, FAI requirements, aerospace documentation, product traceability, and configuration management.

Key Competencies:

• Strong leadership and operational decision-making.
• In-depth understanding of aircraft structural assembly processes.
• Excellent production planning, execution, and problem-solving skills.
• Ability to lead cross-functional teams and meet demanding customer schedules.
• Strong customer interaction and program management capabilities.
• Effective communication, team building, and performance management.