Principal Build Reliability Engineer

Castelion Corporation•Torrance, CA

About The Position

Castelion is seeking a Build Reliability Engineer to ensure the reliability of flight components and assemblies. The role evaluates product and process output data to improve manufacturing quality and represents quality objectives in design and development teams. It supports design for manufacture, inspection and test process development, first-build reviews, production quality analysis, root-cause investigations, containment, non-conforming hardware management, engineering documentation reviews, and production process audits and improvement. The engineer participates in product design reviews to promote design for quality and manufacturability, risk mitigation, and appropriate validation and inspection methods. The position develops inspection plans, measurement methods, walk-down criteria, and objective acceptance criteria; analyzes production quality data and prioritizes issues; and drives corrective actions and controls to prevent recurrence. It also reviews engineering and production documentation for accuracy, completeness, compliance, and quality objectives. The role requires a bachelor's or advanced degree in a relevant engineering or physics field and at least five years of experience in quality, manufacturing, or design engineering. The position may require extended hours or weekend work, travel up to 30%, and lifting more than 50 pounds. Export-control eligibility is required; certain assignments may also require the ability to obtain and maintain a government security clearance or other authorization.

Requirements

Bachelor's or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering, or physics.
At least 5 years of experience in a quality, manufacturing, or design engineering role.
Must be willing to work extended hours and/or weekends as needed.
Must be able to travel up to 30%.
Must be able to lift more than 50 pounds.
Must meet applicable U.S. export-control eligibility requirements: be a U.S. citizen or national, lawful permanent resident, refugee, or asylee, or be eligible to obtain required authorizations.
If the position is designated as requiring it, must be able to obtain and maintain required U.S. government security clearance or other government authorization and meet applicable eligibility requirements.

Nice To Haves

Experience supporting production of complex electromechanical, mechanical, or composites systems in high-volume work centers and/or during production ramp-up.
Knowledge of Lean principles, Six Sigma, Root Cause Analysis and Corrective Action, Advanced Product Quality Planning, metrology, Process Failure Mode and Effects Analysis, Control Plans, and problem-solving approaches.
Commitment to a Lean approach to quality without compromising safety or reliability.

Responsibilities

Evaluate product and process output data to drive improvements in manufacturing quality and represent quality objectives in design and development teams.
Participate in Preliminary Design Reviews and Critical Design Reviews to ensure design for quality and manufacturability, risk quantification and mitigation, and consideration of appropriate validation, inspection, and nondestructive evaluation methods.
Develop design for manufacturability by identifying key characteristics, conducting prototype manufacturability testing, planning First Article and Detailed Inspections, and evaluating previous non-conformances and lessons learned.
Lead inspection planning for new products by identifying features and gages and integrating inspection with planned operations.
Design or procure measurement methods and integrate them with existing processes.
Validate measurement and test methods using process capability and measurement systems analysis statistical tools.
Propose solutions that eliminate the need to verify product conformance through measurement, such as poka-yoke.
Coordinate, schedule, and facilitate objective First Build Reviews covering design intent, requirements, risks, and manufacturability.
Develop and maintain engineering walk-down criteria for major product milestones, providing Production with engineering intent and acceptance criteria.
Identify photo closeout requirements for complete as-built documentation.
Evaluate and analyze the production quality landscape, use data to inform prioritization, and keep product reliability as a primary focus.
Drive quality targets through an appropriate management review hierarchy and ensure controls prevent recurrence.
Lead, facilitate, and participate in root-cause investigations; perform analyses using appropriate quality tools; document causes and corrective actions; and ensure actions prevent recurrence.
Lead containment activities for suspect products and guide inspectors, technicians, and shop supervisors in quarantining suspected products.
Communicate evaluation and disposition status regularly to production leadership.
Support review of issue tickets, ensure design-deviation rationale and documentation are captured, and coordinate management of non-conforming hardware.
Review and approve Engineering Orders, Engineering Masters, Work Orders, specifications, and product-introduction documentation for completeness, accuracy, regulatory compliance, and quality objectives.
Validate that drawings capture all requirements needed to build and inspect hardware.
Develop and update inspection plans as processes or designs change, ensuring inspection and test criteria have objective pass/fail standards.
Assess new processes for safety and product risks, ensure adherence to QMS policies and procedures in the work center, and develop and conduct audits to identify process weaknesses.

Benefits

Meaningful equity for all full-time employees.
Four weeks of paid time off.
Ten company-paid holidays.
Medical plans with 100% employee coverage and 80% dependent coverage.
Dental and vision coverage with 90% employee coverage and 80% dependent coverage.
FSA and HSA options.
401(k) plan.
Paid parental leave, including up to 10 weeks for birthing parents and up to 4 weeks for non-birthing parents, as well as a stated offer of eight weeks for all parents and additional paid pregnancy leave for California employees.
Frequently catered lunches and team meals, plus company-covered meals when extra time or effort is required.
Stocked kitchen with snacks and drinks.
$100 monthly fitness stipend.
Onsite electric vehicle charging.