Staff Quality Engineer - Dimensional Manufacturing Integration

Commonwealth Fusion Systems•Devens, MA

1d•Onsite

About The Position

Commonwealth Fusion Systems (CFS) is seeking a Staff Quality Engineer to serve as the subject matter expert (SME) for dimensional management and quality strategy for our HTS Magnet production and the SPARC Project. In this high-impact role, you will be the technical authority on Geometric Dimensioning and Tolerancing (GD&T), ensuring that novel, first-of-a-kind designs are translated into manufacturable and verifiable hardware. The Staff role will be the technical authority responsible for taking "good enough" prints and collaborating with Manufacturing Engineering to develop the inspection infrastructure, tooling, and process controls required to build them. You will serve as the expert in applying GD&T to real-world fabrication challenges, ensuring that the SPARC project meets its mission through pragmatic, risk-informed quality solutions.

Requirements

BS in Mechanical, Industrial, Material Science or Manufacturing Engineering
Minimum 10+ years of Quality Engineering experience in a manufacturing, assembly or equipment manufacturing environment, specifically focused on transitioning new products to production
GD&T Expertise: Mastery of GD&T (ASME Y14.5) with a proven ability to translate theoretical tolerances into practical manufacturing work instructions
Metrology: Deep knowledge of CMM, Romer Arm, and Laser tracker applied to complex geometries
ISO 9001-2015, Six Sigma, Statistical Process Control (SPC), Process Capability Analysis, PFMEA, Measurement System Analysis (MSA), APQP
GD&T and Metrology Knowledge of cryogenics
Minitab or JMP, MS Excel (including VBA), MS Visio
Excellent communication and organization skills
GD&T and Metrology Knowledge of NDE (non-destructive evaluation) methods including dye penetrant, ultrasonic, eddy current, and x-ray
Ability to occasionally lift up to 50 lbs
Willingness to travel or work required nights/weekends/on-call occasionally
Perform activities such as stooping, climbing, typing, standing, or sitting for extended periods of time
Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics

Nice To Haves

Hardware Assembly: Extensive experience with the assembly of large metallic components, welding processes and Nondestructive Testing
Statistical Tools: Proficiency in Minitab or JMP for conducting Process Capability Analysis and Six Sigma methodologies

Responsibilities

Manufacturing-Driven GD&T Interpretation: Take complex design requirements and work directly with Manufacturing Engineers to determine how to achieve critical tolerances using existing equipment and novel fabrication methods
Proactive Problem Solving: Lead the development of risk-informed QA controls that bridge the gap between design intent and shop-floor reality to positively impact the CFS mission
Inspection Architecture: Architect measurement systems and quality inspection methods specifically designed for the assembly of large metallic components, moving beyond theoretical models to executable floor-level plans
Disposition Leadership: Provide high-level leadership in dispositioning Non-Conformance Reports (NCRs), focusing on "use-as-is" or "rework" justifications based on structural integrity and functional requirements
Process Stabilization: Regularly analyze manufacturing data using control charts and process capability studies to identify where the "build" is diverging from the "print," escalating insights to Operations to drive immediate process adjustments
Sub-system Integration: Facilitate the creation and execution of PFMEAs and Quality Plans for the installation of sub-systems, ensuring that assembly tolerances are managed as the SPARC project scales
Measurement System Analysis (MSA): Lead advanced MSA and Gage R&R studies to ensure that the methods used to measure novel designs are statistically sound and repeatable in a production environment
Mentorship & Oversight: Provide technical coaching to QC Inspectors and Quality Engineers, specifically regarding GD&T interpretation on the shop floor