Job Title: Senior Manager – Test Cell
Reports To: Head of Operations
Division: Engineering / Operations
Department: Project Management
Employment Type: Full-Time, Indirect
Supervisory Responsibilities: Team Leaders, Supervisors, Engineers
Job Summary
The Senior Manager – Test Cell is responsible for leading and managing all aspects of test cell operations, ensuring the safe, efficient, and compliant testing of aircraft engines. This role oversees a cross-functional team and collaborates with internal and external stakeholders to deliver high performance and operational excellence.
Key responsibilities include developing operational strategies, ensuring regulatory compliance, driving continuous improvement initiatives, managing budgets, and preparing the facility and processes for operational readiness. The role requires deep technical knowledge, proven leadership in high-volume engine maintenance environments, and a focus on innovation, quality, and process efficiency.
Key Responsibilities
1. Operational Strategy & ConOps Development (10%)
- Develop and implement strategic plans for test cell operations aligned with organizational goals.
- Lead the development of the Concept of Operations (ConOps) for the test cell, ensuring effective and streamlined processes.
2. Operational Leadership (25%)
- Oversee day-to-day test cell operations, ensuring adherence to testing protocols, safety procedures, and compliance standards.
- Provide leadership and mentorship to a multi-disciplinary team of engineers, supervisors, and technicians.
- Ensure optimal use of test cell resources, tooling, equipment, and consumables.
3. Safety, Compliance & Quality (10%)
- Ensure compliance with aviation regulations and industry safety standards (e.g., FAA, EASA, local regulatory bodies).
- Lead the development and review of test cell operation manuals and technical documentation.
- Support quality assurance efforts through audit participation and corrective action implementation.
4. Financial Management (10%)
- Develop and manage annual budgets for test cell operations, including headcount planning, CAPEX, and OPEX.
- Monitor cost control, resource utilization, and financial alignment with business targets.
5. Performance Optimization & Continuous Improvement (20%)
- Analyze performance metrics such as Turnaround Time (TAT), On-Time Delivery (OTD), and resource efficiency.
- Implement Continuous Improvement (CI), Lean, and Six Sigma methodologies to enhance test processes.
- Identify and eliminate process inefficiencies, improve output quality, and drive innovation.
6. Process Industrialization & Day 1 Readiness (10%)
- Ensure readiness of all systems, procedures, and infrastructure for full-scale operations.
- Oversee ERP system testing, mock trials, and dry runs for process validation prior to operational launch.
7. Risk Management & Business Continuity (10%)
- Identify operational risks and develop robust mitigation plans.
- Ensure uninterrupted test operations and regulatory compliance under all conditions.
8. Stakeholder Collaboration & Communication (5%)
- Liaise with senior leadership, internal departments, OEMs, suppliers, and regulatory agencies.
- Represent the test cell function in cross-functional initiatives and external audits.
Minimum Qualifications
Education
- Bachelor's degree in Aerospace, Mechanical, or Industrial Engineering (or related discipline).
- Master’s degree preferred.
- Professional training or certifications in leadership, operations management, or aviation compliance are an advantage.
Experience
- 10–12 years of experience in a high-volume MRO (Maintenance, Repair & Overhaul) engine testing or operations environment.
- Minimum 5 years in a leadership or managerial role overseeing complex testing or maintenance functions.
- Familiarity with both OEM and third-party engine testing operations is highly preferred.
Key Competencies
- MRO Operations Mastery – In-depth understanding of the full engine lifecycle: disassembly, inspection, testing, and reassembly.
- Leadership & Team Management – Proven ability to lead large, diverse technical teams in a high-performance setting.
- Regulatory Compliance – Knowledge of aviation regulations and quality standards (e.g., FAA, EASA, AS9110).
- Lean & CI Methodologies – Hands-on experience applying Lean, Six Sigma, or other CI frameworks.
- Technical Acumen – Strong knowledge of engine systems and non-destructive testing techniques (e.g., FPI, MPI, Ultrasonic, Eddy Current).
- Project & Change Management – Capable of managing process transitions, facility buildouts, and operational scaling.
- Customer & Stakeholder Management – Ability to engage effectively with OEMs, suppliers, auditors, and internal partners.
- Business & Financial Insight – Experience with budget planning, CAPEX/OPEX control, and KPI-driven management.
- Risk & Crisis Management – Expertise in risk identification and mitigation strategies to maintain operational continuity.
- Process Engineering & Industrialization – Ability to establish or optimize facility layouts, resource plans, and workflow models.
- Vendor & Supply Chain Oversight – Knowledge of parts procurement, warehouse operations, and material flow planning.
- Technology Integration – Strong aptitude for implementing tools, systems, and automation technologies to enhance operational capability.
Additional Requirements
- Willingness to work in shift-based or extended hour environments depending on operational needs.
- Familiarity with ERP systems and digital platforms used in test cell or MRO operations.