Senior Quality Engineer

Worker Type

Regular

Job Description

Summary
The Senior Quality Engineer (QE) is accountable for delivered product quality to customers and for ensuring effective quality controls across the product lifecycle. The QE partners with program, product, and operations teams to eliminate cost and flow disruptions, implement visual factory KPIs, and lead robust problem reporting and CAPA for nonconformances. This role includes both customers facing quality and internal product quality responsibilities.

Position Responsibilities

• Quality Planning and Engineering

• Develop and implement comprehensive quality assurance and quality control plans for components and systems across the product lifecycle.

• Define quality metrics, testing methodologies, and inspection procedures to ensure adherence to quality standards from development through production and sustainment.

• Review manufacturing planning to align quality control points and data collection.

• Coordinate work with Quality Technicians and Inspectors as necessary.

• 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 ensure mutual understanding of requirements and expectations.

• Collaborate with engineering teams to establish quality requirements, specifications, and standards for new product development.

• Provide input on Design for Manufacturability (DFM) and Design for Assembly (DFA) to optimize product quality and efficiency.

• Perform risk assessments and analysis on designs to identify potential quality and reliability risks, and develop mitigation strategies.

• Utilize tools such as Failure Mode and Effects Analysis (FMEA) to systematically assess and prioritize risks and develop appropriate risk mitigation plans.

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• Participate in Product Readiness Reviews (PRR) and coordinate Final Inspection activities.

• Participate in the review of engineering specifications to ensure the inclusion of adequate quality and reliability requirements.

• Lead Quality's contribution to Advanced Product Quality Planning (APQP), ensuring robust planning across all phases (Plan & Define, Product Design & Development, Process Design & Development, Validation, and Launch) and embedding quality requirements into design and manufacturing processes.

• Provide guidance and assistance in quality enhancement strategies and interpretation of workmanship criteria.

• Conduct internal and supplier audit activities, including but not limited to the quality management system, purchasing, contract review, and manufacturing processes.

• Analyze internal and external quality performance and drive measurable improvements aligned with strategic business objectives.

• Defect Management and Corrective Action

• Document and track defects using designated Quality Management Systems, prioritize issues based on severity and impact, and collaborate with cross_functional teams to implement corrective actions.

• Lead complex investigations into product and process nonconformances, field issues, and test escapes, applying advanced problem_solving tools (e.g., 5_Why, Ishikawa diagrams, Design of Experiments, regression analysis, fault tree analysis) to identify true root cause.

• Lead the Material Review Board (MRB) process for nonconforming product, ensuring timely review, risk assessment, and disposition (use_as_is, rework, repair, scrap) in accordance with quality standards and internal processes.

• Coordinate cross_functional MRB meetings (Quality, Engineering, Operations, Supply Chain) to drive 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.

Basic Qualifications (Required Skills & Experience)

• Bachelor's degree in a related discipline, or equivalent combination of education, training, and experience.

• Minimum of 5 - 8 years of related quality engineering experience.

• Experience and strong understanding of DMAIC, FMEA, APQP, Statistical Process Control (SPC), Gage R&R studies, and lean manufacturing methodologies.

• Demonstrated knowledge of ISO 9001, AS9100, and AS9102 standards and audits.

• Knowledge of industry standards and regulations applicable to manufacturing (e.g., IPC_A_610, IPC/WHMA_A_620).

• Ability to communicate with internal/external customers and suppliers to resolve process gaps and apply specified requirements in a cost_effective manner.

• Knowledge of dimensional inspection measurement systems and their application for the inspection of complex products, including a 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 effective corrective and preventive actions.

• Demonstrated ability to drive internal and external DPPM (scrap and rework) reduction and on_time delivery (OTD) improvements, both internally and at suppliers.

• Hands_on experience with quality testing equipment, measurement tools, and inspection techniques.

• Experience with creating and documenting Dimensional data packs and First Article Inspection Reports (FAIs).

Other Qualifications & Desired Competencies

• Demonstrates initiative to work efficiently and streamline processes; normally receives little instruction on day_to_day work and general instructions on new assignments.

• Able to quickly digest complex situations and identify/evaluate risks related to potential paths forward; assists leadership in assessing risks and recommending appropriate courses of action.

• Has a full understanding of one's specialization and uses professional concepts and company objectives to resolve complex issues in creative and effective ways.

• Strong written and verbal communication, analytical, time management, and problem_solving skills.

• Ability to work effectively as an individual contributor and as a member of cross_functional teams.

• Able to excel in a fast_paced, deadline_driven environment where small teams share a broad variety of duties.

• Displays strong initiative and drive to accomplish goals and meet company objectives.

• Takes ownership and responsibility for current and past work products.

• Committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company.

• Demonstrates proficiency with MS Office Suite (Word, Access, PowerPoint, Excel).

• Focuses on teamwork and collaboration, placing the success of the team above individual interests.

• Proven experience mentoring and developing other engineers; able to explain complex quality concepts in clear, practical terms to non_quality stakeholders.

• Acts as a primary quality liaison between Engineering, Operations, Supply Chain, Program Management, and Business/Finance to ensure quality requirements are understood, planned, and executed across programs.

Physical Demands

Ability to work in an office and manufacturing environment (constant).

Regularly required to stand, sit, talk, hear, and use hands and fingers to operate a computer and telephone keyboard (frequent).

Clearance Level

No Clearance

The salary range for this role is:

$91,000 - $138,750

AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills.

ITAR Requirement:

This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements.

Benefits: AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown. For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits.

We also encourage you to review our company website at http://www.avinc.com to learn more about us.

Principals only need apply. NO agencies please.

About AV:

AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best.

We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next.

If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV.

We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status.

ITAR

U.S. Citizenship required