Sr Quality Engineer, Unmanned Systems (UAV/USV)

Senior Quality Engineer

Ideal Aerosmith is a leading supplier of precision inertial guidance test systems, flight motion simulators, innovative defense solutions in support of the warfighter, and a premier provider of aerospace test engineering services, ATE system engineering, and quality contract manufacturing services to the aerospace industry. We're experts and we earn that title every day with our customers through innovative engineering, manufacturing, and sustainment of world-class motion and electric test solutions and services.

Here, we don't just solve complex problems - we redefine what's possible. Every role at Ideal Aerosmith supports a lean culture through continuous improvement - ongoing, incremental enhancements to products, processes, or services aimed at reducing waste and boosting efficiency, customer service, and performance. With a team of skilled problem solvers and a culture that thrives on tackling challenges head-on, we are dedicated to our clients' success. Enjoy competitive benefits, a supportive work environment, and every other Friday off to recharge.

We are seeking a Senior Quality Engineer to architect, establish, and scale the end-to-end quality system supporting system-level integration and production of our Unmanned Aerial Vehicle (UAV) and Unmanned Surface Vehicle (USV) programs. This role is responsible for building quality processes from the ground up and ensuring disciplined execution across engineering, manufacturing, supply chain, and test functions as programs transition from development to rate production. The position partners closely with cross-functional teams to ensure products are built in compliance with configuration, contractual, and regulatory requirements while achieving high levels of first-pass yield, repeatability, and production readiness.

The ideal candidate has experience in aerospace or complex electromechanical environments, with a strong foundation in quality systems, inspection planning, root cause analysis, and production quality control. This role plays a critical function in transitioning advanced platforms from prototype builds to rate-capable production by ensuring robust quality processes are embedded early and scale effectively.

Job Responsibilities

Quality System Development

• Develop and implement quality management systems aligned with ISO-9001 and defense program requirements
• Establish and maintain quality plans, inspection strategies, and acceptance criteria for system-level integration and assembly
• Define and implement process control plans, including key quality checkpoints throughout manufacturing and integration flows
• Ensure alignment between engineering configuration, manufacturing execution, and quality verification processes
• Establish and maintain documentation control, traceability, and audit readiness across all production activities
• Establish and enforce production quality gates, including authority to stop work or prevent release when requirements are not met

Production Quality & Inspection

• Develop and maintain inspection plans, including receiving, in-process, and final inspections
• Support First Article Inspection (FAI) activities in accordance with AS9102 or equivalent standards
• Define acceptance criteria for assemblies, subassemblies, and system-level integration
• Monitor and drive improvements in key quality metrics including first-pass yield, defect rates, and rework hours
• Ensure production-to-test handoff meets defined quality and configuration requirements
• Ensure quality alignment between production, system integration, and test/verification activities, including configuration validation and test readiness

Root Cause & Corrective Action (RCCA)

• Lead root cause investigations for production and field quality issues
• Implement and verify corrective and preventive actions (CAPA)
• Drive systemic improvements to eliminate recurring defects and improve process capability
• Partner with Manufacturing and Engineering to resolve complex integration and assembly issues

Supplier & Incoming Quality

• Collaborate with Supply Chain to ensure supplier quality requirements are defined and enforced
• Support supplier qualification, audits, and performance monitoring
• Establish incoming inspection requirements and risk-based acceptance strategies
• Drive supplier corrective actions and continuous improvement initiatives

Production Readiness & Scaling Support

• Participate in production readiness reviews and rate capability assessments
• Ensure quality systems and controls are scalable from prototype through full-rate production
• Identify quality risks associated with scaling and implement mitigation strategies
• Support capacity planning with quality resource and inspection requirements

Configuration & Compliance

• Ensure strict adherence to configuration-controlled environments
• Support internal and external audits, including customer and regulatory audits
• Ensure compliance with contractual quality requirements and defense program standards
• Maintain traceability of materials, components, and assemblies throughout production lifecycle

Cross-Functional Quality Leadership

• Provide Design for Quality (DFQ) input during product development
• Partner with Manufacturing Process Engineering to embed quality into process design
• Support Program Management with quality risk identification and reporting
• Serve as a key stakeholder in IPT discussions related to production execution and quality performance

Required Qualifications

• Bachelor's degree in Mechanical, Aerospace, Manufacturing, or related Engineering discipline.
• 7–12+ years of experience in aerospace or complex electromechanical manufacturing environments.
• Demonstrated experience establishing or significantly expanding manufacturing capability in a new or growing production environment.
• Experience implementing and maintaining quality systems in regulated or defense environments
• Strong experience with inspection planning, RCCA, and CAPA methodologies.
• Experience supporting production environments transitioning from prototype to production.
• Familiarity with configuration-controlled manufacturing environments.
• Must be eligible to obtain and maintain a DoD Secret security clearance.
• Due to federal contract requirements, candidates must be U.S. citizens

Preferred Qualifications

• Experience with AS9100 / ISO-9001 quality systems
• Familiarity with AS9102 First Article Inspection requirements
• Experience working with ERP, PLM, and digital quality systems
• Experience supporting UAV, aerospace, or defense system production programs
• Experience conducting supplier audits and managing supplier quality

Skill Requirements

• Strong analytical and problem-solving skills with a systems-level mindset
• Ability to lead RCCA efforts and drive data-driven decision making
• High attention to detail and documentation discipline
• Ability to operate effectively in fast-scaling production environments
• Strong cross-functional communication and collaboration skills
• Ability to influence quality outcomes without direct authority

Physical Requirements

• Ability to work on-site in a production environment
• Ability to stand for extended periods
• Ability to lift up to 45 pounds
• Ability to work around electromechanical systems and production equipment

Ideal Aerosmith is an equal opportunity employer committed to fostering a diverse and inclusive workplace. We do not discriminate based on race, color, religion, sex, sexual orientation, gender identity, national origin, disability, age, or any other characteristic protected by law. Our goal is to create a work environment that celebrates diversity and inclusion, where all employees feel respected and valued. We encourage applications from all qualified individuals and strive to provide equal employment opportunities to everyone.