Senior Staff Quality Engineer - Hardware

About the role

This role serves as the primary technical authority for quality excellence across spacecraft structural and propulsion systems. It is a high-impact leadership role designed for an expert who thrives at the intersection of complex aerospace manufacturing and rigorous mission assurance.

Responsibilities

• Develop and enforce quality requirements for spacecraft structural assemblies, subassemblies, including propulsion systems, and components.
• Lead, facilitate, and investigate nonconformances with root cause corrective action (RCCA) methodologies (such as 8D, DMAIC, and other structured problem-solving methods).
• Provide real-time quality support on the manufacturing floor, including developing inspection test procedures, acceptance test procedures (ATP), and overseeing environmental testing quality compliance (vibration, thermal vacuum, EMI/EMC).
• Develop in-process inspection criteria, First Article Inspection plans, and final product acceptance protocols.
• Develop, manage, and support Material Review Board (MRB) dispositions and oversee rework/repair activities.
• Implement incoming inspection process for hardware and materials, and review supplier quality escape reports.
• Collaborate with Systems Engineering to verify that critical-to-quality (CTQ) features are flowed down and verified at build stages.
• Support internal and external audits, including customer and certification audits.
• Manage supplier quality assurance activities for aerospace parts and assemblies.
• Support manufacturing readiness activities including Process Failure Mode and Effects Analysis (PFMEA) and Control Plans.
• Maintain calibration, gaging, and special process control systems in compliance with aerospace standards.
• Train operators and inspectors on inspection methods, specifications, and quality requirements.
• Ensure compliance with contractual quality requirements, ITAR regulations, and ISO/AS9100 standards.
• Support failure investigations and anomaly resolutions for hardware issues.
• Familiar with tracking and reporting supplier performance metrics (OTD, PPM, NCR rates).
• Maintain strict configuration management and traceability of materials, processes, and documentation per standards.
• Review engineering drawings, specifications, and process plans to ensure quality requirements are defined and met.
• Partner with Manufacturing Engineering to develop robust process controls and inspection plans.
• Support design for manufacturability and producibility reviews to ensure quality is built into critical spaceflight hardware.
• Monitor and control special processes (e.g., bonding, welding, soldering) critical to spaceflight qualification.
• Support design reviews, test readiness reviews, and customer acceptance milestones.
• Conduct supplier audits, PPAP reviews, First Article Inspections (FAIs) per AS9102 standards.

Requirements

• B.S. or higher in Engineering (Mechanical, Electrical, Aerospace, Systems, or Industrial)
• 13+ years of experience in a regulated industry (aerospace, robotics, medical device, automotive, or equivalent)
• Deep familiarity with MES (Manufacturing Execution Systems) and AS9102 standards.
• Knowledge of spacecraft subsystems and operations
• Experience operating in a contamination- and ESD-sensitive environment
• Experience testing high-power RF electronics

Preferred Qualifications

• ASQ certifications (CQE, CRE, CMQ/OE) are highly preferred.
• Certified Lean Six Sigma Black Belt with a proven track record of using statistical methods (DOE, SPC, ANOVA) to reduce variability in low-volume, high-complexity manufacturing.
• A history of mentoring mid-level engineers and developing internal training curricula that raised the overall "Quality IQ" of a production team.