The Senior Turbo Assembly Technician is a highly skilled technical expert responsible for leading the precision assembly, inspection, testing, and troubleshooting of turbochargers for high-performance and production automotive applications. This role plays a key part in process optimization, quality assurance, and mentoring of junior staff. The technician ensures complex turbo systems meet stringent performance, safety, and cleanliness standards while supporting engineering changes, prototype builds, and lean manufacturing initiatives.
Independently assemble a wide range of turbochargers (standard, variable geometry, twin-scroll, electric-assist) to detailed specifications and tight tolerances.
Perform rotor balancing, run-in procedures, and functional checks using advanced tooling and fixtures.
Support R&D, prototype, or pre-production builds with non-standard configurations and modified parts.
Diagnose assembly issues, misalignments, part defects, and system failures with minimal supervision.
Implement corrective actions and collaborate with engineering, quality, and supply chain teams for resolution.
Support root cause analysis, FMEA input, and process documentation improvements.
Lead first-article inspections, audits, and final checks to ensure product compliance with design and performance requirements.
Maintain, calibrate, and improve use of precision measuring tools and balancing equipment.
Ensure all builds meet cleanliness, traceability, and torque specification requirements.
Train and mentor junior and mid-level technicians in best practices, SOP compliance, and advanced assembly methods.
Provide guidance on safe work practices, tool usage, and continuous improvement activities.
Act as a subject matter expert for turbo system assembly within the production team.
Identify and lead improvement initiatives related to assembly flow, workstation layout, waste reduction, and part handling.
Collaborate with manufacturing engineers to validate changes in tools, jigs, and procedures.
Support implementation of 5S, visual controls, and quality alerts on the assembly floor.
Expert-level turbocharger assembly, testing, and balancing
Diagnosis and resolution of complex assembly or fitment issues
Leadership in quality, cleanliness, and inspection processes
Mentorship and training of junior assembly staff
Prototype build support and engineering collaboration
Support for lean manufacturing and continuous improvement
Technical documentation, traceability, and compliance oversight
Education:
High school diploma or GED required
Associate degree or technical certification in Automotive Technology, Mechanical Assembly, or Manufacturing Engineering preferred
Certifications:
Lean Six Sigma, IPC/Mechanical Assembly, or OEM turbo system certifications a plus
Experience:
6+ years of experience in turbocharger or rotating equipment assembly in an automotive, aerospace, or precision manufacturing environment
Strong experience with balancing machines, torque tools, test equipment, and inspection processes
Familiarity with prototype development, engineering changes, or new product introduction (NPI) is highly desirable
Technical Skills:
Advanced knowledge of turbocharger systems, components, and failure modes
Proficiency with precision gauges, metrology tools, balancing systems, and pneumatic/electric assembly tools
Ability to interpret complex mechanical drawings, GD&T, BOMs, and work instructions
Soft Skills:
Leadership, mentoring, and effective communication skills
Analytical thinker with a proactive and quality-driven mindset
Excellent documentation and reporting ability
Team-oriented, dependable, and comfortable working in high-urgency environments