Senior Quality Engineer

AeroVironment•Albuquerque, NM

5d•$91,000 - $138,750

About The Position

The Senior Quality Engineer is accountable for product quality delivered to customers and for effective quality controls across the product lifecycle. The role partners with program, product, and operations teams to reduce cost and flow disruptions, implement visual factory KPIs, and lead problem reporting and corrective and preventive action (CAPA) for nonconformances. It covers both customer-facing quality and internal product quality responsibilities. The position develops quality plans and metrics, defines testing and inspection procedures, reviews manufacturing plans, performs process capability analysis, coordinates Quality Technicians and Inspectors, and ensures acceptance criteria reflect customer needs. It works with customers and engineering teams to flow down requirements and establish quality standards for new products, including input on manufacturability, assembly, risk analysis, and product readiness. The role leads Quality’s contribution to APQP, participates in reviews and final inspection, and conducts internal and supplier audits. The Senior Quality Engineer documents and prioritizes defects, leads complex investigations into product and process nonconformances and field issues, and applies problem-solving and statistical methods to find root causes. It leads the Material Review Board process and cross-functional disposition decisions, monitors related metrics, and drives corrective actions and measurable quality improvements. This position requires access to ITAR/EAR-controlled information. Applicants must qualify as a U.S. person or be eligible for an export license; U.S. citizenship is required for this posting. The role works in office and manufacturing environments.

Requirements

Bachelor’s degree in a related discipline, or an equivalent combination of education, training, and experience.
5–8 years of related quality engineering 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.
Ability to communicate with internal and external customers and suppliers to resolve process gaps and apply requirements cost-effectively.
Knowledge of dimensional inspection measurement systems and their use for 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 to determine root causes and define corrective and preventive actions.
Demonstrated ability to improve internal and external DPPM (scrap and rework) and on-time delivery, internally and 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 effectively independently and in cross-functional teams, including 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 clearly to non-quality stakeholders.
Ability to work in office and manufacturing environments; regularly stand, sit, talk, hear, and use hands and fingers to operate computer and telephone keyboards.
Must qualify as a U.S. person under ITAR/EAR or be eligible for an export license; U.S. citizenship is required as stated in the posting.

Nice To Haves

Demonstrates initiative in working efficiently and streamlining processes, with limited day-to-day instruction.
Ability to quickly understand complex situations, evaluate risks, and assist leadership with recommendations.
Ability to apply professional concepts and company objectives to resolve complex issues creatively and effectively.
Strong ownership, initiative, teamwork, collaboration, and commitment to continuous improvement.

Responsibilities

Develop and implement quality assurance and quality control plans for components and systems throughout the product lifecycle.
Define quality metrics, testing methodologies, and inspection procedures for development, production, and sustainment.
Review manufacturing planning to align quality control points and data collection; coordinate work with Quality Technicians and Inspectors as needed.
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, flow down quality requirements, and collaborate with customer representatives to align on requirements and expectations.
Collaborate with engineering teams on quality requirements, specifications, and standards for new product development; provide input on DFM and DFA.
Assess design risks to product quality and reliability, including through FMEA, and develop mitigation strategies.
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 across planning, design and development, process design and development, validation, and launch.
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 processes.
Analyze internal and external quality performance and drive measurable improvements aligned with business objectives.
Document and track defects in designated Quality Management Systems, prioritize issues, and collaborate with cross-functional teams on corrective actions.
Lead investigations into product and process nonconformances, field issues, and test escapes using advanced problem-solving tools to determine root causes.
Lead the Material Review Board process, including risk assessment and disposition of nonconforming product in accordance with quality standards and internal processes.
Coordinate cross-functional MRB meetings to reach data-based disposition decisions and prevent recurrence of known defects.
Monitor and report MRB and disposition metrics and recommend improvements to reduce nonconformance.
Drive corrective action and failure analysis in a timely manner.
Analyze quality data and perform statistical analysis to identify trends and improvement opportunities.
Drive internal and external DPPM reduction and on-time delivery improvements, including at suppliers.
Create and document dimensional data packs and First Article Inspection Reports.
Serve as a primary quality liaison among Engineering, Operations, Supply Chain, Program Management, and Business/Finance.
Mentor and develop other engineers and explain quality concepts to non-quality stakeholders.