The Director of Methods Assembly is a results-driven, strategic, and technical leader responsible for providing overall leadership, direction, and guidance to the Assembly Methods organization. The Director will lead efforts to enhance manufacturing processes and define new product introduction plans while optimizing production capabilities at De Havilland Aircraft of Canada. This position offers a unique opportunity to shape and build the Methods function in support of company goals and objectives.
The ideal candidate will have extensive experience in planning, coordinating, and executing complex manufacturing strategies, ensuring continuous improvement and optimizing production efficiency. This role requires expertise in aerospace manufacturing, strong leadership skills, and a collaborative mindset to drive the development and implementation of new processes, and tools.
Key Responsibilities:
New Program Introduction (NPI):
- Manufacturing Integration: Integrate manufacturing requirements into the overall aircraft build process, ensuring that production capabilities align with engineering specifications and program schedules.
- Creation and Release of Documentation: Coordinate the creation and timely release of aircraft build and supporting documentation, ensuring all production materials meet customer and program specifications.
- Integrated Product Development Teams (IPDT): Lead and engage with IPDTs, ensuring cross-functional alignment between engineering, operations, and quality teams throughout the product lifecycle.
- Change Management: Drive effective change management processes, ensuring all modifications are executed with minimal disruption and full compliance with program requirements.
- First Article Schedule & Delivery: Oversee the creation and delivery of first articles, ensuring they meet design and manufacturing requirements.
Business Process Improvement:
- Process Benchspaning: Regularly benchspan manufacturing processes against industry best practices to identify areas for improvement and optimization.
- Production Problem Resolution: Provide direct support to manufacturing teams, resolving production issues promptly and effectively to maintain schedule and quality.
- Line Support: Offer continuous support to production lines to address and resolve any manufacturing challenges or roadblocks.
- New Technology Analysis: Evaluate new technologies and tools that can improve manufacturing efficiency and product quality, ensuring the company remains competitive within the aerospace sector.
Functional Leadership in Methods & Industrialization:
- Defining Manufacturing Standards: Establish manufacturing standards, processes, and procedures to ensure consistency, quality, and efficiency across all production operations.
- Engagement and Enablement: Develop and execute engagement plans to empower the manufacturing teams with the knowledge, skills, and tools needed for success.
- KPIs and Governance: Define and implement Key Performance Indicators (KPIs) and governance frameworks to track and ensure operational performance meets objectives.
- Training and Development: Lead the development of training and career growth plans for the Methods & Industrialization team, ensuring continuous skill development and knowledge transfer.
- Budgets and Financial Management: Manage the budget for the Methods function, ensuring financial objectives are met and resources are used efficiently.
Education and Experience:
- A Bachelor’s or Master’s degree in Engineering, Aerospace Engineering or related technical field is required.
- Minimum of 10 years of progressive experience in highly complex assembly manufacturing environments, ideally within the aerospace sector.
- At least 5 years of experience in a managerial role, leading multi-disciplinary teams.
- Proven track record in managing the integration of engineering and manufacturing functions, particularly during new program introductions and complex production challenges.
- Strong background in manufacturing, product and process innovation, and continuous improvement techniques.
- Extensive experience managing complex projects, with a proven ability to lead teams through multiple phases of new product development and manufacturing.
Skills and Competencies:
- Proficiency in MS Office 365 Suite (Excel, PowerPoint, Word, Outlook) and MS Project.
- Advanced knowledge of aerospace manufacturing principles, product lifecycle management, and methods engineering.
- Familiarity with cost accounting, cost estimating, and financial management in the context of aerospace manufacturing.
- Demonstrated leadership ability, with experience in managing cross-functional teams across different locations and ensuring alignment on goals and objectives.
- Strong communication skills, both written and verbal, with the ability to present complex information to executive leadership and other stakeholders.
- Problem-Solving & Decision Making:
- Ability to analyze complex manufacturing and technical challenges and develop practical, innovative solutions.
- Exceptional decision-making ability, ensuring that decisions are based on thorough analysis, cost-benefit considerations, and strategic alignment.
- Customer Focus & Interpersonal Skills:
- A strong customer-centric mindset, with a focus on exceeding customer expectations while maintaining efficient manufacturing operations.
- Excellent interpersonal skills, with the ability to work collaboratively with internal teams, suppliers, and external stakeholders.
Working Conditions:
- This is a full-time position based in Calgary, AB.
- Occasional travel may be required to manufacturing sites, suppliers, and customer locations.
- The Director, Methods Assembly must be adaptable and able to work in a fast-paced, dynamic environment where business priorities may shift quickly.
