Foundry Quality Engineer

Location; New Britain, CT

Reports to: Chief Executive Officer / President

Position Type: Full-Time / Permanent

Salary: Competitive compensation package reflective of capabilities and experience

PURPOSE

The Quality Engineer is responsible for overseeing all quality assurance and control processes within the foundry to ensure that aerospace-grade materials and products meet stringent industry standards. This role involves performing inspections, implementing quality control plans, and ensuring compliance with AS9100, NADCAP, and customer-specific requirements. The Quality Manager will also lead efforts to investigate non-conformances, implement corrective actions, and drive continuous improvement initiatives to enhance product quality and process efficiency. Collaboration with internal teams, suppliers, and customers to resolve quality issues and ensure satisfaction is essential. Additionally, the role requires maintaining all quality-related documentation, supporting audits, and ensuring compliance with health, safety, and environmental regulations.competitiveness and profitability.

ESSENTIAL DUTIES AND IMPORTANCE OF JOB RESPONSIBILITIES

Most critical part of the job responsibilities; requires most of the employee’s time and effort.

1. Quality Assurance and Control:
   • Perform inspections and testing on incoming raw materials, in-process products, and final castings to ensure conformance with aerospace specifications.
   • Develop and implement quality control plans for casting processes, including dimensional checks, material properties, and surface finish inspections.
   • Ensure compliance with industry-specific quality standards such as AS9100 and NADCAP.
2. Aerospace Industry Compliance:
   • Ensure that all foundry processes and products meet the stringent quality requirements of the aerospace industry, including traceability, documentation, and record-keeping.
   • Collaborate with the Quality Manager to maintain and update the Quality Management System (QMS) in compliance with AS9100 and customer-specific requirements.
   • Support external and internal audits, preparing documentation, records, and other evidence required for compliance.
3. Non-Conformance and Corrective Actions:
   • Investigate non-conformances related to casting processes and products, using root cause analysis methods such as 8D, 5-Why, or Fishbone Diagrams to identify issues.
   • Work with cross-functional teams to implement corrective and preventive actions (CAPA) and ensure follow-up to verify the effectiveness of these actions.
   • Ensure that all non-conformances and CAPAs are documented and communicated to the appropriate internal and external stakeholders.
4. Supplier Quality Management:
   • Assist in the evaluation and qualification of aerospace material suppliers, ensuring that they meet the required standards for quality, performance, and consistency
   • Conduct supplier audits and reviews to ensure that supplied materials conform to aerospace specifications.
   • Collaborate with suppliers to resolve any material quality issues and implement improvement initiatives.
5. Continuous Improvement:
   • Lead or participate in continuous improvement initiatives, focusing on reducing scrap, minimizing rework, and improving product consistency and reliability.
   • Apply Lean Manufacturing, Six Sigma, and other process improvement tools to identify opportunities for enhancing quality and process efficiency.
   • Support the implementation of Statistical Process Control (SPC) and other statistical quality control techniques to monitor and improve process stability.
6. Process Monitoring and Analysis:
   • Monitor key process parameters and production data to identify trends and potential deviations from aerospace specifications.
   • Analyze quality data, including defect rates, scrap rates, and customer returns, to drive data-based decision-making and improvement initiatives.
   • Conduct Failure Mode and Effects Analysis (FMEA) and other risk assessments to ensure process reliability and prevent defects in aerospace products.
7. Documentation and Reporting:
   • Prepare and maintain all quality-related documentation, including inspection records, test reports, control plans, and non-conformance reports.
   • Generate and present regular reports on quality performance metrics such as yield rates, defect rates, and corrective action status.
   • Ensure that all documentation is properly stored, updated, and accessible for audits and customer reviews.
8. Customer Interaction and Support:
   • Support the resolution of customer complaints by investigating quality issues, performing root cause analyses, and implementing corrective actions.
   • Collaborate with the Quality Manager and Customer Service team to ensure that customer requirements are understood and met throughout the production process.
   • Participate in customer audits and reviews, providing technical support and responding to inquiries regarding product quality and processes.
9. Health, Safety, and Environmental Compliance:
   • Ensure that all quality control processes comply with health, safety, and environmental regulations, particularly in handling hazardous materials used in aerospace foundries.
   • Work with the Environmental, Health, and Safety (EHS) team to integrate safe practices into quality processes and ensure compliance with safety standards.
   • Promote a culture of safety and regulatory compliance within the quality and production team

WORK EXPERIENCE / EDUCATION REQUIREMENTS

Education: 

Bachelor’s degree in Metallurgy, Materials Science, Mechanical Engineering, Industrial Engineering, or a related field..

Experience:

• 3+ years of quality engineering experience in the aerospace or foundry industry, with a strong focus on casting and metal manufacturing processes.
• Hands-on experience with AS9100, NADCAP, and other aerospace industry standards and regulatory requirements.

Technical Skills:

• Strong understanding of foundry processes, including casting, melting, molding, and finishing, with specific experience in aerospace-grade materials.
• Proficiency with quality management tools such as Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), Root Cause Analysis (RCA), and Control Plans.
• Experience with Non-Destructive Testing (NDT) methods, such as X-ray, ultrasonic testing, and dye penetrant inspection, commonly used in aerospace components.
• Familiarity with inspection techniques and equipment such as Coordinate Measuring Machines (CMM), micrometers, calipers, and hardness testers.

Soft Skills:

• Strong analytical skills with the ability to interpret data and make informed decisions based on quality performance metrics.
• Excellent communication skills, both written and verbal, to effectively collaborate with cross-functional teams and communicate findings to management and customers.
• Attention to detail and a commitment to maintaining high standards of quality and reliability.
• Ability to work under pressure, prioritize tasks, and manage multiple projects simultaneously.

Certifications:

• Certified Quality Engineer (CQE) or similar certification preferred.
• Six Sigma Green Belt or Black Belt certification is a plus.

Competencies:

·  Strategic Thinking and Vision:

• Aligns quality initiatives with long-term business goals.
• Develops and implements quality strategies for sustained success.

·  Influence and Collaboration:

• Builds cross-functional relationships to prioritize quality.
• Partners with stakeholders to drive quality improvement.

·  Decision Making and Accountability:

• Uses data to make informed decisions on quality issues.
• Takes ownership of quality outcomes and corrective actions.

·  Coaching and Development:

• Mentors team members, promoting continuous improvement.
• Provides feedback and guidance to enhance team skills.

·  Change Management:

• Leads quality initiatives and manages process changes.
• Encourages innovation and embraces new technologies.

·  Ethical Leadership and Integrity:

• Ensures compliance with regulations and customer standards.
• Acts as a role model for ethical behavior and transparency.

·  Emotional Intelligence and Relationship Management:

• Builds strong, trust-based relationships with stakeholders.
• Demonstrates empathy and active listening to resolve issues.

·  Results Orientation:

• Sets clear quality goals and tracks progress.
• Drives excellence in product quality and process efficiency.

PHYSICAL REQUIREMENTS

• This role requires working in both office and foundry environments, with regular exposure to manufacturing areas that involve noise, heat, and dust.
• Occasional travel may be required for customer and supplier audits.
• Must be able to stand for extended periods during inspections and audits.

POSITION FUNCTIONAL REQUIREMENTS (ADA)

1. Standing
2. Walking
3. Keying
4. Sitting
5. Talking
6. Lifting / Carrying
7. Repetitive motions
8. Hearing

AAP/EEO

The company is an Equal Opportunity/ Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex including sexual orientation and gender identity, national origin, disability, protect veteran status, or any other characteristic protected by applicable Federal, state or local law.

Candidates must be legally authorized to live and work in the United States.  Please note that we are unable to provide immigration sponsorships for this position.  Therefore, applicants who require visa sponsorship or who are currently on a temporary visa status will not be considered.

*This job description is intended to provide an overview of the role and its requirements but is not exhaustive.  Additional responsibilities may be assigned as needed to meet the evolving needs of the business.

How to Apply

Interested candidates should submit their resume, cover letter, and any relevant certifications to ParisJF@xonitek.com with the subject line “General Manager – Foundry”