Sr Quality Assurance Engineer - FAA

The Senior Quality Assurance Engineer shall support the business in the areas of new product development, lean implementation, process capability improvement, daily production support, project management, technical data interpretation/analysis (engineering drawings, specifications, technical publications, component maintenance manuals, purchase orders, etc.), and quality system management.

Principal Activities

• Interface with customer Quality representatives on all Quality-related issues and activities. RCCA, Concession submittals and Quality Clinic
• Knowledge of FAA regulations and standards.
• Advanced problem solving, including analyzing, investigating and following up.
• Drive manufacturing process capability improvements through variation reduction, error-proofing, and implementation of statistical process control.
• Collect and analyze quality data to identify and prioritize opportunities for improvement of products and processes.
• Provide leadership on problem solving teams to drive root cause analysis and Corrective/Preventive Action (CAPA) plans.
• Represent Quality department on the New Product Introduction (NPI) teams. Perform contract review and drive design-for-quality activities.
• Review and approve First Article Inspection reports per AS9102.
• Perform Purchase Order review for existing and legacy programs.
• Review customer Source Control Drawings, Specifications, and Quality requirements.
• Manage major program manufacturing process qualification.
• Support Supplier Quality Engineering for supplier quality development.
• Validate and respond to Corrective and Preventive Action Requests (CAR/PAR) from both internal and external customers.
• Witness the tear down and evaluation of the customer-returned products in the MRO area.
• Participate on Material Review Board (MRB) and Configuration Control Board (CCB) processes.
• Develop process flow charts/diagrams and Process Failure Mode Effects Analysis (PFMEA).
• Create statistically valid control plans for manufacturing processes.
• Use lean and six sigma tools to drive process and product variation reduction.
• Conduct and participate in the internal and external quality system, process, and product audits.
• Provide technical leadership to inspection team members.
• Support product/process certifications and approvals.
• Develops, monitors and analyzes product/process trend data in order to optimize manufacturing performance and minimize product and process variability and associated production costs.
• Develops and establishes problem/process root cause and definitive corrective action plans necessary to reduce Scrap, Rework and Repair costs.
• Coordinates / makes modifications to existing procedures, production processes, engineering specifications, and inspection techniques/plans/procedures. Monitors results necessary to validate improvements.
• Develops product quality plans and inspection methodologies.
• Perform other job-related duties as assigned by Quality Management.

CANDIDATE REQUIREMENTS

Knowledge, Skills & Abilities

• Experience: Minimum of 8 years of progressive experience in aerospace quality and manufacturing. Experience in blueprint reading and Geometric Dimensioning & Tolerancing (GD&T). Experience with various raw materials and manufacturing and quality inspection processes (machining, heat treating, anodizing, painting, NDT, etc.). Experience with flight critical components/systems is a plus.
• Knowledge of FAA Repair Station regulations and requirements.
• Advanced problem solving, including analyzing, investigating, and following up.
• Excellent problem-solving skills aimed at identifying and correcting the root causes of problems
• High ethical standards. Models and supports organization’s goals and values; adapts to changing conditions; demonstrates persistence and overcomes obstacles.
• Proven business/technical writing, presentation, planning, problem solving, organizational, project management and judgement skills.
• Understanding of government contract requirements.
• Understanding of major aerospace prime customer requirements.
• Familiar with FAA Repair Station regulations and requirements.
• Six sigma tools and methodology; green belt or black belt experience is a plus.
• Lean manufacturing practices to improve product/process quality.
• Demonstrated working knowledge of problem solving tools: 5-Whys, Failure mode and effects analysis, 8-D, Pareto, fault tree analysis, and Ishikawa diagrams.
• Aerospace Quality Management Systems: ISO 9001, AS9100, AS9110, FAR 21, FAR 145, and Nadcap requirements.
• Demonstrated ability to create and implement statistically valid control plans and audit plans
• Working ability of inspection metrology and proper application of automated measuring equipment
• Excellent understanding of geometric dimensioning and tolerancing
• Ability to create and/or review failure analysis reports and perform dimensional tolerance stack up analyses
• Experience in industrialization processes such as PPAP, PVI (DVI) with FAI per AS9102
• Thorough understanding of Word, Excel, Power Point, Visio, Project, and other application software

Education

Education: Bachelor of Science degree in technical field, ASQ or extensive verifiable experience in lieu of degree