Methods Engineer

This role is at Spirit AeroSystems, Inc. a wholly owned subsidiary of The Boeing Company, supporting Spirit's Commercial Business Units ("Spirit Commercial"). Spirit Commercial designs and builds commercial aerostructures, including for Boeing Commercial Airplanes, one of Boeing's three business units and the premier manufacturer of commercial jetliners for decades. Spirit Commercial's core products include fuselages, pylons, nacelles and wing components, with a focus on innovative composite and aluminum manufacturing solutions.

The Methods Engineer supports the maintenance and repair organization by developing, standardizing, and optimizing repair methodologies for aircraft structural and sheet-metal components in an aftermarket (MRO) environment. This role ensures engineering intent is converted into clear, executable repair instructions that enable safe, compliant, and efficient aircraft component repairs.

Key Accountabilities:

• Develop, standardize, and maintain repair process documentation, including work travelers, inspection checklists, repair layouts, and job cards.
• Translate engineering data into accurate, operator-friendly repair documentation.
• Verify repair methods meet FAA/EASA Part 145 and manufacturers requirements.
• Ensure consistent format, visual standards, and clear documentation structure.
• Define methods, sequences, tooling, and materials for structural/sheet-metal repairs.
• Collaborate with Design and Stress Engineering to identify and support repair development.
• Analyze repair maintenance feedback to identify recurring issues and implement corrective actions.
• Provide technical training and support to maintenance teams on repair instructions and standards.
• Ensure all work plans, Bill of Materials and documentation comply with manufacturers data, regulatory and internal quality systems.
• Work with Operations, Quality, and Supply Chain to ensure smooth integration of new or updated methods.

Required Qualifications

• Minimum 4+ years of experience in a FAA/EASA Part 145 or equivalent aerospace MRO environment.
• Strong understanding of aircraft structural components, fasteners, corrosion treatment, and metal-forming techniques.
• Experience authoring or reviewing work instructions, repair job cards, and routings for aircraft structures.
• Ability to interpret and apply technical data (SRM, CMM, AMM, SBs, engineering drawings).
• Knowledge of aircraft structural component repair and materials.
• Knowledge of repair documentation standards, quality processes, and regulatory documentation flow.
• Proficiency with Microsoft Office, and familiarity with digital documentation systems or ERP tools.
• Strong written and verbal communication skills with a focus on clarity and compliance.

Preferred Qualifications

• Bachelor's degree in Aerospace, Mechanical, or Manufacturing Engineering, OR technical diploma + 8+ years hands-on MRO experience in structural repair planning or methods engineering.
• Experience in both metallic and composite repair processes.
• Familiarity with aircraft control surfaces, doors, thrust reversers, flight spoilers, and pylons.
• Knowledge of Lean Manufacturing or Six Sigma principles.
• Experience in an aftermarket/repair-station environment supporting repair development and routing.
• FAA Aircraft & Powerplant (A&P) certification is an asset.

Pay is based upon candidate experience and qualifications, as well as market and business considerations.

Summary Pay Range: $67,150 - $103,000

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