Lead Sheet Metal Mechanic in Birmingham

STS Aviation Services is hiring a Lead Sheet Metal Mechanic in Birmingham, United Kingdom. This is a full-time internal opportunity within the Engineering department, reporting to the Head of Production. This hands-on leadership role is responsible for overseeing and supervising an experienced team of Structures technicians while supporting the safe and efficient execution of aircraft production and modification work. The Lead Sheet Metal Mechanic will act as the key focal point for Structures and Mechanical activities, helping ensure workmanship, compliance, programme schedules and task card hours remain on track.

Position Overview

The Lead Sheet Metal Mechanic will provide leadership, planning support and technical oversight across Structures and Mechanical work. Working closely with the B1 Engineer and other stakeholders, this role will help translate planning inputs, constraints, staffing needs and sequencing into practical work plans that support efficient programme delivery.

Key Duties and Responsibilities

• Oversee and supervise an experienced team of Structures technicians, providing strong leadership and support.
• Maintain high standards of workmanship and regulatory compliance.
• Set a positive example to foster a culture of safety, quality and operational efficiency.
• Work with the B1 Engineer to coordinate daily activities and support seamless execution of the production and modification programme.
• Serve as the primary focal point for all Structures and Mechanical activities.
• Monitor progress against allocated task card hours and programme schedules.
• Provide regular updates to the Line Manager, including issues that may impact delivery.
• Transform rough build plan data, including planning inputs, constraints, staffing and sequencing, into a practical unconstrained work plan for the zone and team.
• Continuously refine and re-baseline work plans to optimise workload, resource utilisation and schedule risk.
• Develop and implement detailed work plans aligned with operational needs.
• Factor manpower, tooling, spaces and safety requirements into daily planning.
• Perform proactive levelling and sequencing to maximise throughput.
• Remove major structural sections and items with appropriate structural considerations and safety measures, including stress jacking.
• Maintain compliance with engineering and regulatory requirements.
• Work with stakeholders to ensure Structures solutions meet operational needs and integrate with overall aircraft modification programmes.
• Track adherence to allocated task card hours for Structures maintenance and modifications.
• Manage ProMRO / Customer ERP system time entries and ensure accurate data capture for forecasting and reporting.
• Collaborate with Boeing IE/ME personnel to identify and rectify Non-Conformance issues.
• Initiate and manage the Non-Conformance Report process with Boeing, including documentation, tracking and closure.
• Identify discrepancies between planned and actual hours.
• Perform root cause analysis and implement corrective actions to prevent recurrence.
• Escalate variations to stakeholders including production managers, planners and finance teams.
• Drive timely decision-making.
• Recommend and implement process improvements to optimise efficiency and resource allocation.
• Support data-driven decisions for labour forecasting and project timelines.
• Support Structures system testing, validation and troubleshooting.
• Ensure robust verification of modifications and upgrades.
• Provide mentorship and development for junior Structures personnel.
• Foster a collaborative, safe and achievement-oriented team environment.

Skills And Abilities

• Completed engineering apprenticeship, ideally in Aeronautical Engineering, or military equivalent.
• Minimum of 5 years of aircraft experience.
• Excellent ability to read manufacturers’ drawings and SRMs.
• Familiarity with OEM manuals and standards.
• Proven experience in aircraft production and/or modification programmes.
• Previous supervisory or leadership experience.
• Military aircraft experience preferred.
• Excellent knowledge of Aircraft Systems and structural integration.
• Strong planning, sequencing and resource levelling capabilities.
• Ability to translate rough planning data into actionable work plans.
• Advanced computer and data-management skills.
• Proficient in ERP systems, including ProMRO and others as applicable.
• Proficient in MS Excel, including advanced features.
• Experience with data analysis tools.
• Effective interpersonal and communication skills.
• Ability to liaise with cross-functional teams and Boeing representatives.
• Eligible to work and live in the UK.

Part 145 Training Requirements

• Initial Human Factors Continuation Training.
• Human Factors Initial SFAR Phase 1 and 2 Continuation Training.
• SFAR Phase 1 and 2 Initial EWIS Group 1 and 2, including EWIS Group 1 Module G Continuation Training.
• EWIS Group 1 and 2.
• ETOPS RVSM.