Senior Quality Control Engineer

AeroVironment•San Diego, CA

About The Position

The Senior Quality Control Engineer is accountable for the quality of products and services provided to customers and for ensuring quality controls are met. The role engages program and product resources to eliminate cost drivers and flow disruptions, implement visual-factory operational KPI metrics, and establish effective problem-reporting and corrective and preventive action systems for containment, correction, prevention, and nonconformance documentation. The position has both customer-quality and product-quality responsibilities. The engineer develops quality plans, metrics, testing methodologies, and inspection procedures for CUAS components and systems across the product lifecycle. The role coordinates with technicians, inspectors, and cross-functional teams to establish manufacturing processes, work instructions, inspection and test gates, process capability analysis, and product acceptance criteria. It also reviews customer contracts and purchase orders, communicates with customer representatives, and collaborates with engineering on requirements, design risks, manufacturability, and product readiness. The role leads quality contributions to APQP, performs PPAPs, participates in product readiness and final inspection activities, conducts internal and supplier audits, and drives internal and external quality improvements. It documents and tracks defects, leads complex investigations and root-cause analysis, drives corrective action and failure analysis, and leads the Material Review Board process for nonconforming product. The engineer analyzes quality data, coordinates cross-functional disposition decisions, and mentors and develops other engineers. The position requires work in both office and manufacturing environments. ITAR/EAR compliance requires applicants to qualify as a U.S. person or be eligible for an export license; some positions may require current U.S. citizenship due to contract requirements. The posting states ITAR U.S. Citizenship required.

Requirements

Bachelor's degree in a related discipline, or an equivalent combination of education, training, and experience.
8–12 years of related experience.
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.
Knowledge of dimensional inspection measurement systems and their application to complex products; full understanding of ASME Y14.5 (GD&T).
Expertise in mechanical inspection methods and skills.
Ability to collect, compile, and analyze data using appropriate Six Sigma methods and techniques to determine root causes and corrective or preventive actions.
Ability to support internal and external DPPM reduction and on-time-delivery 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 part of a team 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.
Ability to work in an office and manufacturing environment; regularly stand and sit, talk and hear, and use hands and fingers to operate a computer and telephone keyboard.
ITAR/EAR eligibility: applicants must qualify as a U.S. person or be eligible for an export license; the posting also states U.S. citizenship is required.

Nice To Haves

Demonstrates initiative to work efficiently and streamline processes, and can work with little day-to-day instruction.
Ability to quickly assess complex situations, evaluate risks, and assist leadership in selecting an appropriate path forward.
Ability to apply professional concepts and company objectives to resolve complex issues creatively and effectively.
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.
Focuses on teamwork and collaboration, prioritizing the success of the team.

Responsibilities

Develop and implement comprehensive quality assurance and quality control plans for CUAS components and systems.
Define quality metrics, testing methodologies, and inspection procedures throughout the product lifecycle.
Review manufacturing planning to align quality control points and data collection.
Coordinate work with Quality Technicians and inspectors as needed.
Collaborate with cross-functional teams to establish 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, and flow down new customer requirements to relevant functions.
Correspond with customer representatives 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 considerations.
Assess design quality and reliability risks and develop mitigation strategies, using tools such as 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, 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 Material Review Board process, ensuring timely review, risk assessment, and disposition of nonconforming product in accordance with quality standards and internal processes.
Drive timely corrective action and failure analysis.
Analyze quality data and perform statistical analysis to identify trends and improvement opportunities.
Coordinate cross-functional MRB meetings to support data-based disposition decisions and prevent recurrence of known defects.
Act as a primary quality liaison among Engineering, Operations, Supply Chain, Program Management, and Business/Finance.
Collect, compile, and analyze data to identify root causes and corrective or preventive actions.
Support internal and supplier DPPM reduction and on-time-delivery improvements.
Create and document dimensional data packs and First Article Inspection Reports.
Mentor and develop other engineers and explain quality concepts to non-quality stakeholders.