Junior Engineer - Assembly & Integration

Purpose/Objective

Junior Engineer – Assembly & Integration executes guided subsystem integrations, interprets engineering drawings, ensures torque compliance, and maintains calibration, BoM, and process traceability. This role supports build documentation, raises NCRs, and collaborates with engineering and QA to maintain integration quality and audit preparedness.

Key Responsibilities of Role

Mechanical and Electrical Subsystem Assembly: - Perform installation of structural frames, brackets, antenna mounts, and internal trays using GD&T-verified drawings and mechanical BOMs. - Route harnesses and connectors inside UAV fuselage sections based on wiring schematics and harness drawings; confirm connector mating by ID code and pin alignment. - Support integration of Power Distribution Boards (PDBs) by verifying connector orientation, signal path routing, and secure mounting as per schematic references. - Apply torque using calibrated tools according to defined torque specs (Nm/in-lb), record values on checklist where required, and ensure visual confirmation (torque seal, color marking). Component Fit-Up & Compatibility Troubleshooting: - Verify part fitment and surface alignment using physical mock-ups, coordinate measuring arms, or laser alignment jigs. - Identify mismatched connector gender, harness length deviations, or mounting hole misalignments, and raise Non-Conformance Report (NCR) for resolution. - Recommend alternate routing paths for non-critical harnesses when original path causes interference, with approval from integration engineer. Interpretation of Engineering Drawings and Wiring Schematics: - Independently read mechanical drawings with GD&T annotations, identify tolerancing zones, critical mounting hole locations, and symmetry references. - Interpret wiring schematics including signal paths, ground loops, and shielded line routing; understand polarity marking and connector cross-referencing. - Annotate drawings to mark deviations or undocumented design changes encountered during assembly, and route these notes for review. Kitting Validation and Inventory Feedback: - Validate BoM completeness against issued kits and flag shortages, overages, or alternate part substitutions using batch tags and ERP references. - Maintain segregation of kits by serial numbers and project codes to avoid cross-contamination; support traceability by tagging unused items before return to stores. - Report recurring kitting issues (e.g., missing hardware pack, wrong crimp connector variants) and suggest improvements to the kitting workflow. Tool Calibration Compliance and Handling: - Ensure torque tools, calipers, crimpers, and thermal guns are used only if within calibration window; sign daily pre-use checklist. - Log tool usage in traceability sheets and coordinate tool return for recalibration based on expiration tags or usage cycle flags. - Identify damaged tools (bent torque drivers, cracked handles, faulty gauges) and initiate tool quarantine request with metrology/QA. Technical Documentation and Assembly Traceability: - Complete routing checklists, electrical continuity check logs, torque application sheets, and batch build reports based on platform configuration. - Document any observed fitment issues or undocumented wire color variations in the build log and flag these to QA or Design Engineer. - File completed job sheets into project folders with correct part number, drawing revision, and build serial tagging. PLM System Usage and Revision Tracking: - Access Teamcenter/Windchill to retrieve latest drawing revisions, change notes, and related documentation for assigned assemblies. - Cross-check drawing revision number and configuration ID with build instructions; request clarification for ECRs in process or drawings under review. - Support Engineering Change Request (ECR) logging by capturing part-level impact details during deviation or assembly interruptions. Calibration Log Tracking and Process Support: - Maintain daily calibration board in assigned area, highlighting upcoming expirations and tools under recertification hold. - Support audit teams during calibration record reviews by retrieving usage logs, calibration certificates, and tool tag photos. - Identify repetitive calibration misses or booking delays and recommend improved tracking measures (e.g., barcode-based flagging or digital alerts). Process Compliance, Safety & Quality Coordination: Follow cleanroom-level ESD protocols: - wrist strap validation, conductive mats, safe cable dressing, and connector sealing practices. - Perform Foreign Object Debris (FOD) inspections post-integration and before QA handover using flashlights, air blowers, and magnet wands. - Interface with QA inspectors during in-process quality checks, torque witnessing, or functional test readiness assessments. Continuous Learning and Integration Optimization: - Maintain a structured log of builds executed, tools used, part variants handled, and errors encountered for performance tracking. - Attend knowledge sessions led by Engineers on connector families, torque theory, updated harness trees, or platform-specific quirks. - Propose improvements to assembly fixture layout, part access during integration, or tool routing to improve ergonomics and reduce cycle time.

Technical Competencies

Qualifications and Experience

Educational Background: - BE/BTech in Mechanical, Aerospace, or Industrial Engineering. Work Experience: - 2–4 years in mechanical or electromechanical assembly in UAV or aerospace environments. Industry Knowledge: - Hands-on knowledge of torque procedures, GD&T interpretation, cable routing, and component verification. Familiarity with PLM, BoM management, and aerospace kitting processes.