Head of Operations – Aerostructure Assembly

Head of Operations – Aerostructure Assembly

Designation: Head of Operations

Reporting To: COO / Business Head

Job Purpose

Responsible for leading and managing end-to-end operations of the Aerostructure Assembly Program, including industrialization, facility and tooling readiness, manpower planning, First Article Inspection (FAI), and serial production. This position drives operational excellence while ensuring product quality, on-time delivery, cost control, and full compliance with aerospace quality standards and customer requirements.

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 strict adherence to approved drawings, engineering specifications, assembly sequences, process sheets, and work instructions.
• Track production output, cycle time, productivity, rework, and delivery performance.
• Implement robust shop-floor controls to enable safe, efficient, and quality-focused production.

 Industrialization and FAI

• Direct industrialization activities from technical data review through production readiness and serial manufacturing.
• Collaborate with Engineering and Quality teams to define assembly processes, work instructions, inspection plans, and manufacturing documentation.
• Confirm assembly jig, fixture, drill template, special tool, gauge, and inspection equipment readiness.
• Plan and lead FAI preparation and execution in line with applicable customer requirements and AS9102, where applicable.
• Coordinate closure of FAI observations and non-conformances to secure customer approval for production.

Production Planning and Execution

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

Manpower Management and Development

• Determine manpower requirements for assembly engineers, supervisors, skilled assemblers, riveting technicians, and supporting functions.
• Lead recruitment, training, competency assessment, and qualification of assembly personnel.
• Define clear roles, responsibilities, performance objectives, and productivity standards.
• Develop a technically capable workforce to meet aerospace manufacturing and assembly requirements.

Quality and Customer Coordination

• Ensure compliance with AS9100, relevant aerospace customer requirements, and approved manufacturing processes.
• Partner with Quality Assurance to maintain product conformity, traceability, inspection readiness, and documentation compliance.
• Coordinate with customer representatives during technical reviews, inspections, FAI activities, and production progress meetings.
• Lead root-cause analysis, corrective actions, continuous improvement, and reduction of rework and rejection.
• Maintain 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 impacting assembly execution.
• Support CAPEX and OPEX planning, cost monitoring, and optimal utilization of manpower and infrastructure.

Continuous Improvement

• Implement Lean Manufacturing, 5S, visual management, and standardized operating practices.
• Drive improvements in labour productivity, assembly cycle time, first-pass yield, and cost efficiency.
• Set up performance dashboards and periodic reviews to track operational KPIs.
• Foster 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.