Lead Quality Engineer (Hardware Products and Manufacturing Processes)

AeroVironment • Huntsville, AL

1d

About The Position

AV is looking for a Lead Quality Engineer to join the Quality Team to work with our Kinetic Interceptor Program to ensure products and processes meet established standards and regulations. The Lead Quality Engineer will work across a broad range of disciplines with an emphasis on product/process quality assurance, defect analysis and prevention and QMS management. Responsibilities include creating solutions to anticipate and mitigate defects and provide guidance to the kinetic interceptor team resolve defected solutions. Quality Assurance Planning: • Develop and implement comprehensive quality assurance and quality control plans for forward leaning DoD weapon systems • Define quality metrics, testing methodologies, and inspection procedures to ensure adherence to quality standards throughout the product lifecycle. • Review manufacturing planning to align quality control points and data collection. • Collaborate with program team to plan and conduct quality assurance audits across the Kinetic Interceptors team and ensure compliance to quality standards and specifications. Quality Assurance in Design Phase: • Collaborate with engineering teams to establish quality requirements, specifications, and standards for new product development projects. • Conduct design reviews to evaluate weapon system designs for manufacturability, reliability, and compliance with quality standards and regulations. • Provide input on design for manufacturability (DFM) and design for assembly (DFA) considerations to optimize product quality and efficiency. • Perform risk assessments and analysis on designs to identify potential quality and reliability risks, and develop mitigation strategies to address them. • Utilize tools such as Failure Mode and Effects Analysis (FMEA) to systematically assess and prioritize design risks and develop appropriate risk mitigation plans. Testing and Inspection: • Develop and execute verification and validation tests to ensure that designs meet quality requirements and specifications. • Coordinate testing activities with design and testing teams, analyze test results, and provide recommendations for design improvements or modifications as needed. • Conduct thorough testing and inspection of hardware/software components and assemblies to identify defects, deviations, and non-conformities. • Perform functional, reliability, environmental, and performance testing to validate system specifications and requirements. Defect Management: • Document and track defects using designated Quality Management Systems, prioritize issues based on severity and impact, and collaborate with engineering teams to implement corrective actions. • Investigate root causes of defects and non-conformities and propose preventive measures to mitigate future occurrences. Process Improvement: • Continuously evaluate and improve quality control processes and procedures to enhance system quality, efficiency, and reliability. • Identify opportunities for process optimization, automation, and standardization to minimize errors and improve productivity. Supplier Quality Management: • Collaborate with sub-contractors and suppliers to establish quality requirements, conduct audits, and ensure compliance with quality standards and specifications. • Monitor sub-contractor and supplier performance, address quality issues proactively, and drive continuous improvement initiatives to enhance overall system quality. Documentation and Reporting: • Prepare detailed quality documentation, including inspection reports, test plans, and quality records, to provide traceability and accountability for quality activities. • Generate regular quality performance reports and metrics to track key quality indicators and communicate performance trends to stakeholders.

Requirements

• You must be a US citizen
• You must have an active SECRET level security clearance
• Bachelor's degree in related discipline is required or equivalent combination of education, training, and experience
• Minimum of 8 – 12 years of related experience
• Strong understanding of quality management principles, methodologies, and tools (e.g., FMEA, Six Sigma, SPC)
• Hands-on experience with quality testing equipment, measurement tools, and inspection techniques.
• Knowledge of industry standards and regulations applicable to manufacturing (e.g., ISO 9001, AS9100, IPC-A-610).
• Excellent analytical skills and attention to detail, with the ability to identify root causes of quality issues and implement effective solutions.
• Strong communication and interpersonal skills, with the ability to collaborate effectively with cross-functional teams and external stakeholders.

Responsibilities

• Develop and implement comprehensive quality assurance and quality control plans for forward leaning DoD weapon systems
• Define quality metrics, testing methodologies, and inspection procedures to ensure adherence to quality standards throughout the product lifecycle.
• Review manufacturing planning to align quality control points and data collection.
• Collaborate with program team to plan and conduct quality assurance audits across the Kinetic Interceptors team and ensure compliance to quality standards and specifications.
• Collaborate with engineering teams to establish quality requirements, specifications, and standards for new product development projects.
• Conduct design reviews to evaluate weapon system designs for manufacturability, reliability, and compliance with quality standards and regulations.
• Provide input on design for manufacturability (DFM) and design for assembly (DFA) considerations to optimize product quality and efficiency.
• Perform risk assessments and analysis on designs to identify potential quality and reliability risks, and develop mitigation strategies to address them.
• Utilize tools such as Failure Mode and Effects Analysis (FMEA) to systematically assess and prioritize design risks and develop appropriate risk mitigation plans.
• Develop and execute verification and validation tests to ensure that designs meet quality requirements and specifications.
• Coordinate testing activities with design and testing teams, analyze test results, and provide recommendations for design improvements or modifications as needed.
• Conduct thorough testing and inspection of hardware/software components and assemblies to identify defects, deviations, and non-conformities.
• Perform functional, reliability, environmental, and performance testing to validate system specifications and requirements.
• Document and track defects using designated Quality Management Systems, prioritize issues based on severity and impact, and collaborate with engineering teams to implement corrective actions.
• Investigate root causes of defects and non-conformities and propose preventive measures to mitigate future occurrences.
• Continuously evaluate and improve quality control processes and procedures to enhance system quality, efficiency, and reliability.
• Identify opportunities for process optimization, automation, and standardization to minimize errors and improve productivity.
• Collaborate with sub-contractors and suppliers to establish quality requirements, conduct audits, and ensure compliance with quality standards and specifications.
• Monitor sub-contractor and supplier performance, address quality issues proactively, and drive continuous improvement initiatives to enhance overall system quality.
• Prepare detailed quality documentation, including inspection reports, test plans, and quality records, to provide traceability and accountability for quality activities.
• Generate regular quality performance reports and metrics to track key quality indicators and communicate performance trends to stakeholders.

Benefits

• AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level