Senior Aerospace Quality Engineer - FAI & Supplier Quality

Expleo Group; Washington (District of Columbia); On-site; USD 69,000 - 115,000; Full time

Benefits offered by this job

Competitive compensation

Comprehensive benefits

Paid holidays and PTO

Career development

Job summary

Expleo Group USA is seeking experienced Aerospace Quality Engineers to support aerospace programs focused on product quality assurance, inspection planning, FAI, supplier quality, and continuous improvement initiatives.

Responsibilities include developing quality plans for aircraft modules, defining inspection criteria, coordinating cross-functional teams, and leading PFMEA-driven quality improvements across composite fabrication and production.

Qualifications

• Bachelor's Degree in Engineering, Quality, Manufacturing, Aerospace, or a related technical discipline.
• Equivalent combination of education and relevant aerospace quality experience may be considered.
• 5+ years of quality engineering experience within aerospace, aviation, defense, or advanced manufacturing environments.
• Strong background supporting composite manufacturing processes and aerospace quality systems.
• Experience developing and maintaining inspection plans, quality documentation, and inspection methodologies.
• Demonstrated experience creating, executing, and supporting First Article Inspections (FAI).
• Strong understanding of blueprint reading, GD&T, engineering drawings, and technical specifications.
• Experience conducting root cause investigations and implementing corrective and preventive actions.
• Knowledge of aerospace quality standards, quality management systems, and manufacturing process controls.
• Proficiency utilizing quality metrics, inspection methodologies, and process improvement tools.
• Strong communication, collaboration, and stakeholder management skills.
• Experience working directly with suppliers to establish quality requirements and inspection methodologies.
• Experience defining supplier quality control plans and supplier quality processes.
• Hands-on experience with PFMEA development, facilitation, and implementation.
• Knowledge of AS9100, AS9102, and aerospace quality standards.
• Experience supporting composite aircraft structures, unmanned aerial systems (UAS), UAVs, or aerospace assemblies.
• Background in supplier audits, process audits, and supplier qualification activities.
• Certified Quality Engineer (CQE) certification or equivalent quality credential.
• Familiarity with statistical analysis, process capability studies, and quality improvement methodologies.
• Experience supporting Airbus aerospace programs or advanced aerospace manufacturing environments.

Responsibilities

• Develop and implement quality plans for aircraft modules, assemblies, and components.
• Ensure product compliance with drawings, specifications, aerospace standards, and customer requirements.
• Support production readiness activities by establishing effective inspection and verification processes.
• Drive continuous improvement initiatives focused on product quality, process capability, defect reduction, and operational performance.
• Participate in design reviews, manufacturing reviews, and production readiness activities.
• Collaborate with Engineering, Manufacturing, and Program teams to ensure quality requirements are effectively integrated throughout the development and production lifecycle.
• Support implementation of risk-based quality strategies and process controls.
• Create and maintain detailed inspection plans for composite and structural aircraft components.
• Define critical characteristics, inspection requirements, acceptance criteria, and sampling methodologies.
• Collaborate with Engineering and Manufacturing teams to ensure inspection requirements align with product intent and manufacturing processes.
• Establish quality checkpoints throughout fabrication, assembly, integration, and production activities.
• Support implementation of risk-based inspection strategies and process control methodologies.
• Develop quality documentation and inspection standards to support production and customer requirements.
• Create, coordinate, and execute First Article Inspections (FAI) in accordance with aerospace industry standards.
• Review engineering drawings, specifications, and Bills of Materials (BOMs) to verify all product requirements have been met.
• Prepare and maintain FAI documentation packages and inspection reports.
• Support corrective action activities resulting from nonconformances identified during FAI efforts.
• Ensure compliance with AS9102 and customer-specific First Article Inspection requirements.
• Coordinate cross-functional teams to successfully complete FAI activities and drive product readiness.
• Provide quality engineering support for composite fabrication, bonding, assembly, curing, and structural integration processes.
• Evaluate manufacturing processes to identify quality risks and opportunities for improvement.
• Support root cause investigations and corrective action implementation related to production issues and nonconformances.
• Partner with Manufacturing Engineering teams to improve process capability, product quality, and first-pass yield.
• Assist in validation and implementation of new manufacturing processes and production changes.
• Support continuous improvement initiatives focused on quality performance and manufacturing excellence.
• Collaborate with suppliers to establish effective quality controls, inspection requirements, and product acceptance criteria.
• Support supplier qualification activities, audits, and ongoing supplier development initiatives.
• Review supplier quality documentation, inspection plans, process controls, and corrective action responses.
• Assist in resolving supplier quality issues impacting production schedules, product conformity, or customer requirements.
• Evaluate supplier performance metrics and support supplier continuous improvement activities.
• Partner with Supply Chain and Manufacturing teams to ensure supplier quality performance supports program objectives.
• Participate in PFMEA (Process Failure Mode and Effects Analysis) activities to identify and mitigate manufacturing and process risks.
• Support development of control plans and process controls based on PFMEA outputs.
• Lead root cause analysis and problem-solving activities utilizing: 8D Problem Solving, Root Cause Corrective Action (RCCA), 5 Why Analysis, Fishbone Diagrams, Statistical Process Control (SPC)
• Drive defect reduction, process improvement, and quality performance initiatives throughout production.
• Support quality KPI development, reporting, and trend analysis.
• Promote a culture of quality, accountability, and continuous improvement across the organization.

Skills

Quality engineering

Aerospace industry knowledge

Root cause analysis

Problem solving

Communication & stakeholder mgmt

PFMEA

Education

Bachelor's Degree in Engineering or related technical discipline

CQE certification

Job description

Expleo Group USA is seeking experienced Aerospace Quality Engineers to support aerospace programs focused on product quality assurance, inspection planning, FAI, supplier quality, and continuous improvement initiatives.

Responsibilities include developing quality plans for aircraft modules, defining inspection criteria, coordinating cross-functional teams, and leading PFMEA-driven quality improvements across composite fabrication and production.