Quality Control Inspector CRO

Berry Aviation, Inc. • San Marcos, TX

41d • Onsite

About The Position

The Quality Control Inspector is responsible for performing inspections of aircraft, engines, appliances, and aircraft components to ensure maintenance, repair, overhaul, alteration, and inspection activities comply with applicable regulatory requirements, approved technical data, customer requirements, and the company’s quality standards. This position supports safe and compliant operations by identifying discrepancies, verifying workmanship, maintaining accurate inspection documentation, and ensuring maintenance activities are completed in accordance with FAA regulations, company procedures, and customer requirements. The Quality Control Inspector works closely with the Director of Quality/Chief Inspector and maintenance personnel to perform inspections, verify compliance, and identify quality concerns within the repair station environment.

Requirements

• Must be able to read, write, speak, and understand English.
• Strong verbal and written communication skills.
• Ability to work independently with minimal supervision while maintaining attention to detail.
• Ability to prioritize tasks and respond effectively in a dynamic aviation maintenance environment.
• Ability to interpret technical manuals, regulatory requirements, and detailed work instructions.
• Strong organizational skills and commitment to quality and safety.
• Required FAA Airframe and Powerplant (A&P) Certificate or ability to provide verifiable experience supporting issuance of a Repairman Certificate.
• Minimum of 18 months of experience in aircraft maintenance and/or quality inspection within an airline or FAA Part 145 repair station environment.
• Recent experience performing quality control inspections.
• Experience interpreting aircraft maintenance manuals, component maintenance manuals, and technical data.
• Experience using inspection tools, measuring equipment, and applicable test equipment.
• High School Diploma or equivalent.

Nice To Haves

• Experience with turboprop and/or special mission aircraft, including but not limited to: SA226/SA227 DHC-6 Twin Otter DHC-8 EMB-120 King Air Citation 500 Series Lear 35
• Component repair and overhaul operations
• EASA requirements
• AS9100 Quality Management Systems
• DCMA 8210.1 requirements & experience

Responsibilities

• Perform incoming, preliminary, hidden-damage, in-process, and final inspections of aircraft, engines, appliances, components, and related maintenance activities using appropriate precision measuring instruments and approved inspection methods.
• Inspect internal and normally inaccessible areas for hidden damage, wear, corrosion, erosion, overheating, contamination, cracking, distortion, improper previous repairs, missing parts, foreign-object damage, or other discrepancies.
• Compare inspection findings against the applicable service limits, repair limits, overhaul requirements, and rejection criteria.
• Ensure that damage exceeding published repair limits is not repaired without approved or otherwise acceptable technical data, as applicable.
• Inspect repaired or replaced features to confirm compliance with approved dimensions, fits, clearances, finishes, torque requirements, and acceptance criteria.
• Verify that mandatory replacement items—including seals, packings, gaskets, cotter pins, locking devices, bearings, filters, and other items identified by technical data—are replaced as required.
• Verify that required functional, operational, pressure, leakage, electrical, hydraulic, pneumatic, calibration, or acceptance tests are completed using the procedures and test limits specified in the applicable technical data.
• Ensure failed test results are documented and that the component is returned for troubleshooting, corrective action, and repeat testing.
• Verify that test adapters, caps, plugs, protective devices, safety devices, and required preservation materials are installed following testing.
• Confirm that final test reports are traceable to the component part number, serial number, work order, test equipment, technician, inspector, and date.
• Review all inspection records, work orders and forms to ensure maintenance personnel have completed and properly signed off all inspection tasks and cleared all open discrepancies.
• Document all teardown and hidden-damage inspection findings in the applicable work order, inspection record, discrepancy report, or component inspection form.
• Verify the identity of each article, including nomenclature, manufacturer, part number, serial number, quantity, modification status, and customer work-scope requirements.
• Confirm that the customer’s reported discrepancy, reason for removal, maintenance history, and requested work scope are documented.
• Ensure that required independent inspections, duplicate inspections, critical-task inspections, and Required Inspection Items are completed by appropriately authorized personnel.
• Verify test-equipment configuration, test-medium suitability, environmental conditions, and required test parameters before accepting test results.
• Witness functional tests when required by the applicable manual, work instruction, customer requirement, or inspection plan.
• Verify that rejected or nonconforming parts are clearly identified, documented, controlled, and dispositioned through the approved material-review or nonconformance process.
• Ensure scrapped parts are mutilated or otherwise rendered unusable when required by company procedures or customer instructions.
• Perform or witness teardown inspections at the stages required by the applicable CMM, overhaul manual, work instruction, or inspection plan.
• Verify that parts remain protected from damage, corrosion, contamination, electrostatic discharge, foreign objects, and environmental deterioration throughout the maintenance process and are properly identified and tagged with the correct serviceability status and disposition.
• Verify maintenance, repair, overhaul, modification, and alteration activities are completed in accordance with approved technical data, regulatory requirements, customer requirements, and company procedures.
• Verify that inspection criteria, dimensional limits, repair limits, test requirements, torque values, special processes, and acceptance standards are clearly identified in the work package.
• Ensure that precision measuring equipment, special tooling, fixtures, gauges, test stands, and test equipment are appropriate for the required task and are within their calibration interval at the time of use and have the necessary accuracy, resolution, and range for the characteristic being inspected.
• Confirm that personnel performing inspections, tests, nondestructive testing, welding, plating, heat treatment, or other special processes are properly trained, qualified, and authorized when required.
• Review test results for completeness, confirm that actual readings are recorded and within allowable limits specified in the applicable manufacturer’s technical data.
• Ensure inspection results are traceable to the individual article, work order, inspection operation, inspector, equipment used, and date of inspection.
• Ensure that parts and materials received for installation are eligible for use and meet applicable regulatory, customer, purchase-order, and technical-data requirements.
• Verify applicable shelf-life, storage-life, cure-date, batch, lot, heat, and material-control information.
• Identify and quarantine any article or documentation suspected of being unapproved, counterfeit, altered, incomplete, or otherwise unacceptable.
• Verify that parts requiring nondestructive testing, dimensional inspection, material testing, or engineering evaluation are properly identified and routed for the required examination.
• Coordinate additional work requirements with the Lead Technician, Production Supervisor, and Director of Quality/Chief Inspector when inspection findings exceed the original customer-authorized work scope.
• Review nondestructive inspection reports and other special-process certifications for completeness, acceptability, and traceability.
• Perform daily in-process inspections of ongoing maintenance activities and reviews of all inspection records, forms and tags to ensure maintenance personnel are signing off inspection checklists progressively and all inspection findings & corrective actions have been documented on the work order with all required information as outlined in the Repair Station Quality Control Manual and 14 CFR Part 43.
• Confirm that replacement parts have the correct part number, modification status, eligibility, traceability, and serviceability status.
• Confirm that required process controls are followed for cleaning, plating, painting, bonding, sealing, curing, heat treatment, welding, machining, and other special processes.
• Stop work or reject work when materials, processes, workmanship, documentation, tools, or inspection results do not meet applicable requirements.
• Exercise return-to-service authority only when specifically authorized by BAI and within the limitations of the individual’s certificate, inspection authorization, training, and company-issued authorization.
• Work with the Director of Quality/Chief Inspector to ensure that the quality-control procedures established in the Repair Station Quality Control Manual, EASA Quality Manual, and AS9100 Quality Manual are implemented and followed by all personnel.
• Identify and document nonconforming conditions, procedural deviations, and quality-system deficiencies.
• Initiate or support corrective actions and verify that deficiencies are resolved before the affected aircraft, component, or maintenance record is approved.
• Immediately notify the Director of Quality/Chief Inspector of any condition that may affect regulatory compliance, product conformity, or airworthiness.
• Support internal, customer, FAA, EASA, AS9100, and other regulatory or quality-system audits.
• Assist with investigations involving defects, escapes, repeated failures, warranty returns, suspected unapproved parts, and customer complaints.
• Participate in continuous-improvement activities related to component inspection methods, workmanship standards, inspection planning, and defect prevention.
• Provide technical guidance to maintenance and inspection personnel regarding documentation, inspection standards, component acceptance criteria, and quality-control procedures.
• Perform other job-related duties assigned by the Director of Quality/Chief Inspector.

Benefits

• Equal employment opportunity in all aspects of the employer-employee relationship.
• All conditions and privileges of employment are administered to all employees without discrimination or harassment because of race, religious creed, color, age, sex, sexual orientation, gender identity, national origin, religion, marital status, medical condition, physical or mental disability, military service, pregnancy, childbirth and related medical conditions, special disabled veteran status, or any other classification protected by federal, state, and local laws and ordinances.
• Compliance with all applicable state or local fair employment laws that forbid discrimination or harassment on the basis of other protected characteristics.
• Verification of employment eligibility in accordance with the Immigration Reform and Control Act.
• Participation via E-Verify.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: High school or GED