Head- Prototype Manufacturing process & Assembly Integration

Job Summary : The Head of eVTOL Prototyping, Manufacturing Process & Assembly Integration will lead the end-to-end journey of transforming aircraft design into flight-ready prototypes and scalable production. This role owns prototype build strategy, manufacturing process development, tooling/fixture design, and full-aircraft assembly integration (structures, propulsion, avionics, electrical, and systems), ensuring the eVTOL platform moves efficiently from concept to certified, production-ready aircraft. Key Responsibilities 1. Prototyping Leadership Own the strategy, planning, and execution of full-scale and sub-scale eVTOL prototype builds Translate design engineering outputs (CAD/PLM) into manufacturable prototype build packages Drive rapid iteration cycles between design, test, and manufacturing teams 2. Manufacturing Process Development Design and industrialize manufacturing processes for airframe structures and related subsystems Develop process plans, work instructions, routings, and standard operating procedures (SOPs) Lead Design for Manufacturing & Assembly (DFMA) reviews with design engineering Build the roadmap from low-rate initial production (LRIP) to full-rate production (FRP) Select and qualify manufacturing processes specifically composite layup/curing 3. Assembly Integration Own final assembly line (FAL) design, sequencing, and station-by-station build strategy Lead systems integration into the airframe. Define and implement jigs, fixtures, tooling, and assembly automation Ensure fit, form, and function compliance during integration; resolve build non-conformances 4. Quality, Safety & Compliance Ensure manufacturing and assembly processes comply with aerospace quality standards & DGCA regulations Implement inspection plans, first article inspection (FAI), and non-conformance/CAPA processes 5. Team & Cross-Functional Leadership Mentor and lead a multi-disciplinary team: manufacturing engineers, prototype technicians, assembly integration engineers, tooling designers Partner closely with Design Engineering, Systems Engineering, Test & Flight Operations, Supply Chain, and Quality teams Manage relationships with external vendors, fabrication partners, and suppliers Own budgeting, resource planning, and program timelines for prototyping and assembly functions 6. Continuous Improvement & Scale-up Drive lean manufacturing, 5S, and Kaizen practices on the shop floor Develop the strategy for scaling from prototype to series production, including facility/line planning Evaluate and implement automation, digital manufacturing (MES/PLM integration), and Industry 4.0 tools Experience Required 12–18+ years in aerospace/aircraft manufacturing, prototyping, and assembly integration, with at least 4–5 years in a leadership role. Prior eVTOL, UAV, helicopter, or aircraft OEM experience strongly preferred. Education Bachelor's/Master's degree in Aerospace, Mechanical, Manufacturing, or Production Engineering Additional certifications in Lean Manufacturing, Six Sigma, or Aerospace Quality Systems (AS9100) preferred Requirements Deep hands-on knowledge of aircraft structures, composites, and metallic assembly techniques Experience with manufacturing engineering tools (CAD/CAM, PLM, MES, Six Sigma/Lean) Proven track record of taking a program from prototype to production Strong leadership, cross-functional collaboration, and stakeholder management Excellent problem-solving skills in a fast-paced, first-of-kind product environment Familiarity with certification requirements for eVTOL/UAM aircraft is a strong plus