Engineer, Quality

Quality Engineer - Thermal Spray Coatings

Reports to: Quality & Safety Manager, Surface Technologies US

Work Location: Kymera – CASL Spring Houston TX (On Site)

FLSA Status: Salaried Exempt

Position Summary:

The Quality Engineer – CASL Houston is a technical quality role responsible for supporting quality assurance, process control, inspection, calibration, and continuous improvement across machining, coating, and thermal spray operations. This position provides technical leadership in quality engineering, process development, auditing, measurement systems, root cause analysis, and corrective action while ensuring compliance with customer requirements, ISO 9001, AS9100, and applicable regulatory standards.

The role serves as a key technical resource for quality systems, process controls, calibration programs, customer requirements, and process improvement. The individual will work cross-functionally with Engineering, Operations, Inspection, Laboratory, and Leadership to identify and resolve quality issues, improve process capability and consistency, support customer and regulatory requirements, and drive sustainable improvements in product quality, operational performance, and customer satisfaction.

Essential Duties and Responsibilities:

Lead quality assurance, process control, and compliance activities across machining, surface preparation, coating, and thermal spray operations.

Ensure compliance with customer requirements, internal standards, ISO 9001, AS9100, and applicable regulatory requirements.

Serve as the site technical resource for quality systems, process controls, measurement systems, calibration, and continuous improvement.

Review customer purchase orders, drawings, specifications, and technical requirements to ensure capabilities and quality requirements are understood and met.

Escalate or initiate containment/stop-work when significant quality or safety risks are identified.

Develop and maintain quality procedures, work instructions, process maps, inspection plans, control plans, and SOPs.

Lead process improvement initiatives focused on defect prevention, process capability, efficiency, and consistency.

Support qualification and validation of manufacturing, coating, thermal spray, and inspection processes.

Establish process controls, KPIs, and quality metrics to monitor performance.

Utilize PFMEA, Control Plans, SPC, MSA, Gauge R&R, risk assessments, and statistical analysis to improve process capability.

Support new equipment, process, product, and technology implementation activities.

Develop and maintain the site's calibration management system, including procedures, intervals, records, and traceability.

Coordinate internal and external calibration activities and evaluate out-of-tolerance conditions for potential product impact.

Ensure measurement traceability to nationally recognized standards.

Support calibration laboratory development consistent with ISO/IEC 17025 principles.

Improve measurement systems through MSA, Gauge R&R, correlation studies, and related techniques.

Provide technical oversight and support for visual, dimensional, material, and process inspections.

Support Inspectors and Laboratory personnel with inspection methods, acceptance criteria, and customer requirements.

Verify critical environmental and process conditions affecting coating and thermal spray quality.

Review inspection and process data to identify variation, trends, and potential deficiencies.

Support inspection plans, testing requirements, containment, and disposition of nonconforming material.

Lead root-cause investigations, NCRs, CARs, CAPA, and customer complaint resolution.

Apply structured problem-solving tools such as 5-Why, Fishbone, Pareto, and 8D.

Analyze scrap, rework, NCRs, complaints, audit findings, and process data to identify systemic issues.

Develop and implement corrective and preventive actions and verify their effectiveness.

Drive continuous improvement focused on reducing defects, variation, rework, and customer complaints.

Support customer and supplier quality issues, corrective actions, audits, and technical inquiries.

Prepare and support First Article Inspection (FAI), Pilot Lot, and other customer-specific quality documentation.

Support customer qualification, certification, and approval activities.

Assist with technical reviews of drawings, specifications, data cards, and process requirements.

Communicate with customer and regulatory quality organizations as required.

Lead and support internal, customer, supplier, ISO 9001, AS9100, and regulatory audits.

Maintain audit readiness through documentation, traceability, and process adherence.

Identify audit findings and ensure timely root cause, corrective action, and closure.

Verify corrective action effectiveness and maintain required objective evidence.

Maintain quality documentation including inspection plans, NCRs, CARs, CAPA, FAI reports, audit records, calibration records, and process documentation.

Prepare quality reports covering KPIs, trends, customer issues, corrective actions, and improvement initiatives.

Use statistical, spreadsheet, reporting, and presentation tools to analyze and communicate quality performance.

Escalate significant quality or customer issues to the Quality Manager and site leadership.

Provide technical guidance and mentorship to Inspectors I–III, Laboratory personnel, and production employees.

Support training and qualification in inspection methods, measurement systems, quality procedures, and customer requirements.

Provide functional oversight and help prioritize inspection, audit, calibration, and corrective action activities.

Promote accountability, quality awareness, disciplined problem solving, and continuous improvement.

Partner with Engineering, Production, Operations, Inspection, Laboratory, Supply Chain, and Leadership to resolve quality issues.

Support new product introduction, process development, equipment implementation, and process validation.

Serve as a key technical point of contact for quality matters within the facility.

Support supplier and customer quality concerns as required.

Occasional travel, up to 10%, may be required to support other locations, customers, suppliers, audits, training, or business needs.

Support the Quality Manager and site leadership with quality initiatives, certification activities, special projects, and other duties as assigned.

Supervisory Responsibilities: No direct supervisory responsibilities, but acts as technical leader.

Qualifications:

Bachelor's degree in Quality Engineering, Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Engineering Technology, or related technical field required. Equivalent combinations of education and/or experience may be considered.

Minimum 5 years of progressive experience in Quality Engineering, Quality Assurance within a manufacturing environment. Experience with thermal spray processes or surface coatings required. Strong background in high-precision machining, aerospace manufacturing, or related heavy industrial sectors preferred.

Demonstrated experience developing, implementing, and maintaining Quality Management Systems (QMS).

Experience establishing, improving, or supporting calibration laboratories, metrology systems, and measurement traceability programs preferred.

Experience supporting or leading ISO 9001 and/or AS9100 certification programs and audits.

Demonstrated experience leading root cause analysis and corrective action processes.

Experience supporting or leading audits (internal and external).

Proven leadership experience mentoring or guiding quality and production personnel.

Certifications (Preferred)

ASQ Certified Quality Engineer (CQE)

ASQ Certified Calibration Technician (CCT)

AS9100 or ISO9001 Auditor Certification

Skills and Competencies:

Advanced knowledge of Quality Management Systems (QMS), including ISO9001 and AS9100 requirements.

Strong understanding of machining, coating, thermal spray, and surface preparation processes. Experience leading audits and driving corrective actions. Advanced proficiency in Microsoft Excel, including complex formulas (e.g., XLOOKUP, INDEX/MATCH ), data validation, nested logic, and custom reporting. Strong working knowledge of the broader Microsoft Office Suite (Word, PowerPoint, Outlook) to format, analyze, and present operational data effectively. Prior experience with MetaLab software is preferred, but not required.

Ability to influence and lead quality and safety initiatives.

Strong communication and collaboration skills across all levels of the organization.

High level of accountability, judgment, and decision-making capability.

Continuous improvement mindset with focus on efficiency and defect reduction.

Physical Requirements:

Ability to stand, walk, and perform inspections for extended periods.

Ability to lift up to 50 pounds as needed.

Ability to bend, kneel, crouch, reach, and perform physical tasks as required.

Ability to wear required PPE, including safety glasses, hearing protection, gloves, and steel-toe boots.

Ability to work in environments with