Senior Engineer - Quality Control Engineering

AeroVironment•San Diego, CA

4d•$100,500 - $142,275•Hybrid

About The Position

The Senior Quality Control Engineer (QE) is accountable for the overall delivered quality of products and/or services to customers and ensures quality controls are met. The QE engages program and product resources to identify and eliminate cost drivers, identify and eliminate flow disruptions and implement visual factory operational KPI metrics. The QE establishes effective Problem Reporting and CAPA systems for Containment, Correction & Prevention Actions and Documentation of non-conformances. The Quality Engineer will have both Customer Quality responsibilities or Product Quality responsibilities, in addition to the general responsibilities outlined.

Requirements

Bachelor's degree in related discipline is required or equivalent combination of education, training, and experience.
Minimum of 8 - 12 years of related experience.
Experience and a strong understanding of Define, Measure, Analyze, Improve, Control (DMAIC), FMEA, APQP, Statistical Process Control (SPC), Gage R&R Studies and lean manufacturing methodologies.
Demonstrated knowledge of ISO 9001, AS9100, AS9102 standards and audits.
Knowledge of industry standards and regulations applicable to manufacturing (e.g., IPC-A-610, IPC/WHMA-A-620).
Acts as a primary quality liaison between Engineering, Operations, Supply Chain, Program Management, and Business/Finance to ensure quality requirements are understood, planned, and executed across programs.
Knowledge of dimensional inspection measurement systems and their application for the inspection of complex products – a full understanding of ASME Y14.5 (GD&T).
Expertise in mechanical inspection methods and skills.
Ability to collect, compile and analyze data (using the appropriate six sigma methods and techniques); to determine both the actual root causes of identified problems and required corrective (preventive) actions to prevent recurrence.
Able to affect internal and external DPPM (scrap and rework) reduction and OTD improvements both internally and at our suppliers.
Hands-on experience with quality testing equipment, measurement tools, and inspection techniques.
Experience with creating and documenting Dimensional data packs and First Article Inspection Reports (FAIs).
Demonstrates initiative to work efficiently and to streamline processes.
Normally receives little instruction on day-to-day work, general instructions on new assignments.
Has ability to quickly digest complex situations and identify/evaluate risks related to the potential paths forward.
Able to assist leadership in assessing risks for appropriate path forward considering all factors.
Has a full understanding of one's specialization and uses professional concepts and company objectives to resolve complex issues in creative and effective ways.
Strong written/verbal communication, analytical, time management and problem-solving skills.
Ability to work well as both an individual contributor and as a member of a team.
Able to excel in a fast-paced, deadline-driven environment, where small teams share a broad variety of duties.
Displays strong initiative and drive to accomplish goals and meet company objectives.
Takes ownership and responsibility for current and past work products.
Is committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company.
Demonstrates proficiency using MS Office Suite (Word, Access, PowerPoint, Excel).
Focuses on teamwork, collaboration and puts the success of the team above one's own interests.
Proven experience mentoring and developing other engineers; able to explain complex quality concepts in clear, practical terms to non‑quality stakeholders.
Must qualify as a U.S. person under ITAR/EAR regulations.
Some positions will require current U.S. Citizenship due to contract requirements.

Responsibilities

Develop and implement comprehensive quality assurance and quality control plans for CUAS components and 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.
Coordinate work with Quality Technicians and inspectors as necessary.
Collaborate with cross-functional teams to ensure robust manufacturing processes and work instructions are in place, and that inspection and test gates (incoming, in-process, and final) are defined at the appropriate stages of the build.
Perform process capabilities analysis on key characteristics; implementing Inspection and Quality Plans.
Ensure product acceptance criteria reflects the customer's definition of fitness for use.
Review customer contracts and purchase orders to identify requirements and flow down new customer requirements to all functions.
Correspond, as required, with customer representatives to ensure a thorough understanding of their needs and expectations.
Collaborate with engineering teams to establish quality requirements, specifications, and standards for new product development.
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.
Participate in Product Readiness Reviews (PRR) and coordinate Final Inspection activities.
Participate in the review of engineering specifications to ensure the inclusion of adequate quality and reliability requirements.
Lead Quality’s contribution to Advanced Product Quality Planning (APQP).
Perform PPAP's (production part approval process).
Provide guidance and assistance in quality enhancement strategies and the interpretation of workmanship criteria.
Conduct internal and supplier audit activities including but not limited to quality management systems, purchasing, contract review process, and manufacturing.
Drive trend improvements on the internal & external quality in support of strategic business objectives.
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.
Lead complex investigations into product and process nonconformances, field issues, and test escapes, applying advanced problem-solving tools (e.g., 5-Why, Ishikawa, DOE, regression analysis, fault tree analysis) to identify true root cause.
Lead the Material Review Board (MRB) process for nonconforming product, ensuring timely review, risk assessment, and disposition (use‑as‑is, rework, repair, scrap) in accordance with quality standards and internal processes.
Responsible for driving corrective action and failure analysis in a timely manner.
Analyze quality data and perform statistical analysis to identify trends and improvement opportunities.
Coordinate cross‑functional MRB meetings (Quality, Engineering, Operations, Supply Chain) to drive data‑based disposition decisions and prevent recurrence of known defects.