Senior Manufacturing Integration & Industrialisation Consultant

About the role

PHAREA is seeking a Senior Manufacturing Integration & Industrialisation Consultant to support a major greenfield aerospace manufacturing project in the United Arab Emirates. As Lead Consultant, you will consolidate the existing manufacturing basis, close key technical gaps, prepare controlled inputs for industrial flow simulation and support the maturation of the production layout. Subject-matter experts may complement you when highly specialised expertise is needed.

Key responsibilities

• Review, challenge and consolidate existing manufacturing processes and technical data.
• Define and validate manufacturing routings by product or flow family.
• Challenge cycle-time, capacity, batch-size, WIP and buffer assumptions.
• Review product-to-machine allocation and equipment interfaces.
• Consolidate controlled input data for industrial process and material-flow simulation and interface with the Simulation Supplier.
• Review simulation outputs, bottlenecks, material flows and proposed layouts.
• Support the industrial integration of forging and ring-rolling processes.
• Develop and/or consolidate thermal processing and heat treatment requirements, including billet heating, reheating/equalisation, cooling/quenching and final heat treatment.
• Address manufacturing constraints of nickel-based, titanium, steel and aluminium aerospace alloys.
• Identify interfaces with utilities, material handling, inspection, NDT, laboratory and other industrial systems.
• Identify technical risks, open assumptions and missing technical data.
• Coordinate with client stakeholders, equipment OEMs, the Simulation Supplier and engineering teams.
• Provide structured knowledge transfer to the client's permanent technical resources.

Required profile

• Highly experienced industrial professional who has supported the industrialisation or development of complex manufacturing facilities, ideally in aerospace or engine-component manufacturing.
• Significant experience across several of: aerospace manufacturing, forging and ring rolling, metallurgy and advanced alloys, heat treatment, manufacturing engineering, production routing and cycle-time validation, industrial layout and material flow.
• 20 to 25+ years of experience, in roles such as Manufacturing Engineering Manager, Industrialisation Manager, Manufacturing/Process Engineering Lead, Forging & Ring Rolling Expert, Metallurgy/Heat Treatment Lead or Manufacturing Integration Consultant.
• Initial mobilisation on site in Al Ain, UAE is preferred; a hybrid/remote model may be considered later.

Required skills

• Strong expertise in thermal processing and metallurgy, including furnace, forging press, reheating, ring rolling, quenching and heat treatment sequences.
• Knowledge of pyrometry environments and standards such as AMS2750 is highly desirable.