Senior Quality Control Engineer

AeroVironment•San Diego, CA

2d•$100,500 - $153,250

About The Position

The Senior Quality Control Engineer is accountable for the overall quality of products and services provided to customers and ensures that quality controls are met. The role engages program and product resources to identify and eliminate cost drivers and flow disruptions, and to implement visual-factory operational KPI metrics. It establishes effective problem-reporting and CAPA systems for containment, correction, prevention, and documentation of non-conformances. The position has both customer-quality and product-quality responsibilities. The engineer develops and implements quality assurance and control plans for CUAS components and systems; defines quality metrics, testing methods, inspection procedures, and acceptance criteria; and aligns quality-control points and data collection with manufacturing plans. The role coordinates technicians and inspectors, collaborates with cross-functional teams on manufacturing processes and work instructions, performs process-capability analysis, and ensures inspection and test gates are defined throughout the build process. The role reviews customer contracts and purchase orders, communicates with customer representatives, and flows customer requirements through the organization. It works with engineering on quality requirements and specifications for new products, design-for-manufacturability and design-for-assembly considerations, and design risk assessments. The engineer participates in product readiness reviews, coordinates final inspections, contributes to APQP, performs PPAPs, provides workmanship guidance, conducts internal and supplier audits, and drives quality trends and improvement. The engineer documents and tracks defects, prioritizes issues, and works with engineering teams on corrective actions. The position leads complex investigations into product and process nonconformances, field issues, and test escapes using advanced problem-solving and statistical tools. It leads the Material Review Board process, coordinates cross-functional disposition decisions, drives timely corrective action and failure analysis, and identifies trends and opportunities to prevent recurrence. The position requires working in office and manufacturing environments and access to ITAR/EAR-controlled information. Applicants must qualify as a U.S. person or be eligible for an export license; the posting also states U.S. citizenship is required.

Requirements

Bachelor's degree in a related discipline, or an equivalent combination of education, training, and experience.
8–12 years of related experience.
Experience and strong understanding of DMAIC, FMEA, APQP, Statistical Process Control, Gage R&R studies, and lean manufacturing methodologies.
Knowledge of ISO 9001, AS9100, and AS9102 standards and audits.
Knowledge of manufacturing industry standards and regulations, such as IPC-A-610 and IPC/WHMA-A-620.
Ability to act as the primary quality liaison among Engineering, Operations, Supply Chain, Program Management, and Business/Finance.
Knowledge of dimensional inspection measurement systems and their application to complex products; full understanding of ASME Y14.5 (GD&T) and expertise in mechanical inspection methods and skills.
Ability to collect, compile, and analyze data using appropriate Six Sigma methods and techniques; identify root causes and corrective or preventive actions to prevent recurrence.
Ability to affect internal and external DPPM reduction and OTD improvements, including at suppliers.
Hands-on experience with quality testing equipment, measurement tools, and inspection techniques.
Experience creating and documenting dimensional data packs and First Article Inspection Reports.
Strong written and verbal communication, analytical, time-management, and problem-solving skills.
Ability to work independently and as a team member in a fast-paced, deadline-driven environment.
Proficiency with Microsoft Office Suite, including Word, Access, PowerPoint, and Excel.
Proven experience mentoring and developing other engineers and explaining complex quality concepts to non-quality stakeholders.
Must qualify as a U.S. person under ITAR/EAR or be eligible for an export license; the posting states U.S. citizenship is required.

Nice To Haves

Demonstrates initiative to work efficiently and streamline processes, receiving little day-to-day instruction and general instructions for new assignments.
Ability to quickly understand complex situations, evaluate risks and potential paths forward, and assist leadership in assessing risks.
Full understanding of the specialization and ability to use professional concepts and company objectives to resolve complex issues creatively and effectively.
Strong teamwork and collaboration, with a focus on team success.
Strong initiative and drive to accomplish goals and meet company objectives.
Takes ownership and responsibility for current and past work products.
Commitment to learning from mistakes and improving personal, team, and company performance.

Responsibilities

Develop and implement quality assurance and quality control plans for CUAS components and systems.
Define quality metrics, testing methodologies, and inspection procedures across 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 establish robust manufacturing processes, work instructions, and incoming, in-process, and final inspection and test gates.
Perform process-capability analysis on key characteristics and implement Inspection and Quality Plans.
Ensure product acceptance criteria reflect the customer's definition of fitness for use.
Review customer contracts and purchase orders, identify requirements, and flow new customer requirements down to all functions.
Correspond with customer representatives as needed to understand 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 and design for assembly to optimize product quality and efficiency.
Assess design risks to quality and reliability and develop mitigation strategies, including through FMEA.
Participate in Product Readiness Reviews and coordinate Final Inspection activities.
Review engineering specifications for adequate quality and reliability requirements.
Lead Quality's contribution to APQP and perform PPAPs.
Provide guidance on quality enhancement strategies and interpretation of workmanship criteria.
Conduct internal and supplier audits, including audits of quality management systems, purchasing, contract review, and manufacturing.
Drive internal and external quality-trend improvements in support of strategic business objectives.
Document and track defects in designated Quality Management Systems, prioritize issues by severity and impact, and collaborate with engineering on corrective actions.
Lead investigations into product and process nonconformances, field issues, and test escapes using advanced problem-solving tools to identify root causes.
Lead the MRB process for nonconforming products, including timely review, risk assessment, and disposition in accordance with quality standards and internal processes.
Drive 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 with Quality, Engineering, Operations, and Supply Chain to make data-based disposition decisions and prevent recurrence of defects.