Senior Staff Mechanical Engineer – Aerospace Gearing

Woodward is committed to creating a great workplace for all team members. Our company and its members are committed to acting with integrity being respectful and accountable to one another and staying humble and driven whilemaintainingthe highest professional and ethical standards.

We are steadfastly committed to attracting the best talent across ourcommunitiescreating a rewarding workplace. Together we are fulfilling our purpose to design and deliver energy control solutions our partners count on topowera clean future.

Woodward supports our members wellbeing and regularlybenchmarks withother companies in our industry to offer an extensive Total Reward package for this position.Salary will bedeterminedby the applicants education experience knowledge skills and abilities as well as internal equity and alignment with market data.

Estimatedhourlybase pay: $145000(Minimum) - $181000(Midpoint) - $218000(Maximum)

• All members included inannualcash bonus opportunity.

• 401(k) match (4.5%)

• Annual Woodward stock contribution (5%)

• Tuition reimbursement and Training/Professional Development opportunities for all members

• 12 paid holidays

• Industry leading medical dental and vision Insurance upon date of hire

• Vacation / Sick Time / Vacation Buy-up / Short Term Disability / Bereavement leave.

• Paid parental leave.

• Adoption Assistance

• Employee Assistance Program including mental health benefits.

• Member Life & AD&D / Long Term Disability / Member Optional Life

• Member referral bonus

• Spouse / Child Optional Life / Optional AD&D / Healthcare and Dependent Care Flexible Spending

• Voluntary benefits including:

• Home / Auto Insurance discounts

• Whole Life Insurance / Critical Illness Insurance / Legal Assistance / Military Leave

Key Responsibilities:

Advanced Gear Process Development & Industrialization

• Lead end-to-end development of aerospace-qualified gear manufacturingprocesses developmentincluding spur helical bevel and spline gears.

• Define and document:

• Process flows PFMEAs control plans and work instructions

• Key Characteristics (KCs) and Critical-to-Quality (CTQ) features

• Process capability requirements (Cp/Cpk) for critical gear geometry

• Work cooperatively with gearing designs to improve performance & manufacturability of new gearing products

• Develop andoptimizemachining processes including:

• Hobbing shaping skiving broaching

• Profile and generating grinding

• Honing lapping and superfinishing

• Establish robust process control strategies for:

• Tooth profile accuracy pitch variation lead/helix error

• Surface finish residual stress and distortion control

• Define machining parameters tooling strategies and thermal controls to ensure repeatability in ultra-tight tolerance aerospace components.

• Lead process validation (IQ/OQ/PQ) and AS9102 First Article Inspection (FAI).

• Drive continuous improvement:

• Reduction of transmission error and gear noise

• Improved process capability and yield

• Implementation of advanced machining techniques and in-process monitoring

Supplier Development & Special Process Management

• Serve as technical authority for gear manufacturing suppliers and special process providers.

• Lead supplier qualification and audit activities to ensure compliance with:

• AS9100 quality systems

• Aerospace customer requirements

• Internal engineering specifications

• Oversee and manage NADCAP-controlled special processes including:

• Heat treatment (carburizing nitriding induction hardening)

• Shot peening and residual stress control

• Surface treatments (coatings plating corrosion protection)

• Non-destructive testing (MPI FPI ultrasonic)

• Ensure detailed andaccuratetechnical requirement flow-down including:

• Gear macro- and microgeometry specifications

• Surface integrity and metallurgical requirements

• Full traceability and certification needs

• Partner with suppliers on:

• Process capability improvement initiatives

• Root cause corrective action (RCCA 8D)

• Monitor supplier performance via KPIs and support make vs. buy decisions.

Quality Engineering & Inspection (Precision Components)

• Define and implement advanced inspection strategies for aerospace precision components with emphasis on gearing.

• Establish andvalidatemeasurement systems (MSA Gage R&R) for:

• Gear profile lead pitch runout and composite error

• Surface finish waviness and microgeometry

• Utilize analytical inspection equipment (e.g.Klingelnberg Gleason Zeiss).

• Ensure compliance with:

• AGMA ISO DIN and aerospace standards

• Customer and regulatory requirements

• Lead and support:

• AS9102 First Article Inspection (FAI)

• Internal customer and regulatory audits

• Drive structured root cause investigations addressing:

• Transmission error and NVH performance issues

• Contact pattern deviations and load distribution

• Surface distress wear and fatigue

• Implement SPC and continuous monitoring of critical characteristics.

• Ensure full traceability documentation and configuration control for flight hardware.

Manufacturing & Technical Leadership

• Provide hands-on support to resolve complex machining and finishing issues on the shop floor.

• Collaborate with design engineering on:

• Manufacturability (DFM)

• Tolerance stack-up and performance requirements

• Mentor engineers and technicians in aerospace manufacturing best practices.

• Interface cross-functionallywith Design Quality Supply Chain and Program Management.

Key Skills:

• Effective written and verbal communication skills including presentations (Customer internal and management). Writes and communicates critical reports. Leads complex design reviews internally and Customer. Expert technical writing skills (procedures reports etc.)

• Competent complex problem solving/troubleshooting skills for both components and subsystems.

• Promotes a cross-functional project team environment communicates withCustomersand leads small teams. Mayparticipatein setting technical direction/product strategies.Providestechnical problems-solving guidance to others.

• Strongexpertisein:

• Gear cutting and finishing processes

• Gear metrology and inspection

• GD&T and precision tolerancing

• Experience with:

• AS9100 quality systems

• AS9102 FAI requirements

• CNC and gear manufacturing equipment

• NADCAP special processes and supplier audits

• Familiarity with aerospace OEM requirements (Boeing Airbus etc.)

• Lean Six Sigma certification

• Advanced knowledge of gear analysis and inspection systems

• Background in tribology and gear system performance

Other Qualifications:

• Bachelors degree in a relevant field and 12 years of applicable experience

• Certified Technician or equivalent technical certification

• Experience with precision ball screw manufacturing is preferred and adds value for aerospace actuation systems. Familiarity withthe following would be great tohave:

• Thread grinding thread rolling and whirling processes

• Heat treatment and distortion control of long slender components

• Precision assembly preload setting and end-of-line functional testing

• Lead accuracy positioning error backlash control and preload optimization

• Friction efficiency and wear characteristics in high-load applications

• Lead measurement travel variation analysis preload verification and torque-to-rotate testing

• Precision measurement techniquessimilar togearing

This position requires use of information which is subject to the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). All applicants must be U.S. Persons within the meaning of the ITAR and EAR or eligible to obtain all required authorizations from the U.S. Department of State and/or the U.S. Department of Commerce. The ITAR defines a U.S. Person as a U.S. citizen or national lawful permanent resident (i.e. Green Card holder) or a protected person (e.g. asylee or refugee).

Woodward is an equal opportunity employer and does not discriminate in hiring or employmenton the basis ofrace color religion sex (including sexual orientation and gender identity) national origin age disability protected veteran status or any other category protected under federal state or local laws.

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