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. The role ensures operational excellence, product quality, on-time delivery, cost control, and full compliance with aerospace quality standards and customer requirements.

Industry: Areospace

Key Responsibilities:

Aerostructure Assembly Operations

• Oversee aircraft structural assembly operations, including subassembly, major assembly, and final assembly, as applicable to the program.
• Manage assembly activities for aircraft fuselage, wing structures, tail structures, frames, panels, brackets, and other structural components.
• Ensure execution in line with 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 deliver safe, efficient, and quality-focused production.

Industrialization and FAI

• Lead industrialization efforts from technical data review through production readiness and into serial manufacturing.
• Collaborate with Engineering and Quality teams to define assembly processes, work instructions, inspection plans, and manufacturing documentation.
• Ensure assembly jigs, fixtures, drill templates, special tools, gauges, and inspection equipment are fully prepared.
• Plan and lead FAI preparation and execution based on 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, capacity assessments, manpower deployment, and shift schedules.
• Ensure achievement of production targets, customer delivery timelines, and program milestones.
• Detect bottlenecks and implement corrective actions to enhance throughput and operational efficiency.
• Review daily production performance and conduct regular discussions with cross-functional teams.
• Ensure efficient material kitting, work-in-progress control, tool availability, and prevention of foreign object debris (FOD).

Manpower Management and Development

• Plan manpower needs 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, applicable aerospace customer requirements, and approved manufacturing processes.
• Partner with Quality Assurance to maintain product conformity, traceability, inspection readiness, and documentation adherence.
• Coordinate with customer representatives during technical reviews, inspections, FAI activities, and production progress meetings.
• Drive 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 the assembly facility, utilities, workstations, tools, fixtures, and inspection infrastructure are ready and operational.
• Coordinate with Tooling, Engineering, Procurement, and Supply Chain teams to ensure timely availability of resources.
• Identify and address technical and operational constraints that may impact assembly progress.
• Support CAPEX and OPEX planning, cost monitoring, and efficient utilization of manpower and infrastructure.

Continuous Improvement

• Deploy Lean Manufacturing, 5S, visual management, and standard operating practices.
• Improve labour productivity, assembly cycle time, first-pass yield, and cost efficiency.
• Create performance dashboards and run 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.
• Demonstrated experience leading assembly operations, preferably including industrialization, FAI, and serial production.
• Practical knowledge of aircraft structural assembly practices, 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 setup.
• 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 sound operational decision-making.
• Thorough understanding of aircraft structural assembly processes.
• Strong production planning, execution, and problem-solving skills.
• Capability to lead cross-functional teams and deliver against demanding customer schedules.
• Strong customer engagement and program management ability.
• Effective communication, team development, and performance management.