Lead Inspection Engineer - Metrology & NDE Level 3

Job Description Summary

The Lead Inspection Engineer - Metrology & NDE Level 3 is responsible for leading inspection strategy, execution, and continuous improvement for critical aerospace components and systems. This role combines deep metrology expertise with NDE Level 3 certifications to develop, qualify, and oversee inspection methods that ensure product safety, quality, and regulatory compliance. The engineer serves as the technical authority for NDE and dimensional inspection, mentors Level 1/2 inspectors and engineers, and partners closely with design, manufacturing, and quality teams to drive robust inspection processes across the value stream, including active participation in NPI producibility reviews and design-for-inspectability.

Job Description

Roles and Responsibilities

Technical Leadership - Metrology & NDE

* Serve as the technical authority for metrology and all assigned NDE methods (e.g., UT, RT, PT, MT, ET, CT) at the site or business unit.

* Participate as a reviewer and provide direction on inspection strategies during producibility reviews for NPI programs, ensuring inspectability, process capability, and alignment with customer and regulatory requirements.

* Develop and approve inspection procedures, work instructions, and acceptance criteria in accordance with customer, regulatory, and industry standards (e.g., NAS, ASTM, ASME, EN).

* Design and validate inspection methods, including gaging concepts, fixturing, measurement strategies, and NDE techniques for complex geometries and advanced materials.

* Lead method qualifications and capability studies (e.g., MSA, Gage R&R, POD studies, repeatability and reproducibility analysis).

* Interpret complex indications and measurement results, providing disposition guidance and escalation for non conformances.

* Own and maintain calibration and verification strategies for inspection equipment, ensuring traceability to national and international standards.

NDE Level 3 Responsibilities

* Act as NDE Level 3 in accordance with applicable standards (e.g., NAS 410, SNT-TC-1A, ISO 9712 or equivalent).

* Develop, qualify, and approve NDE techniques and written practices for all covered methods.

* Certify and recertify Level 1 and Level 2 personnel, including developing training content, administering examinations, and defining on-the-job training plans.

* Provide expert interpretation of NDE results, including complex defect characterization, false-call analysis, and root-cause support.

* Lead NDE audits and compliance activities, interfacing internal, customer, and regulatory auditors.

* Monitor and introduce new NDE technologies, tools, and digital solutions (e.g., advanced UT, phased array, CT, automated inspection).

Metrology & Measurement Systems

* Lead the dimensional inspection strategy, including CMM programming, laser scanning, optical measurement, and portable metrology systems.

* Optimize measurement programs and setups to reduce inspection cycle time while improving accuracy and robustness.

* Establish and maintain measurement system capability, including uncertainty budgets, calibration intervals, and environmental controls.

* Collaborate with design engineering on GD&T definition, datum schemes, and tolerancing to ensure inspectability and alignment with manufacturing capability.

* Implement digital inspection workflows, including model-based definition (MBD), digital twins, and data-driven inspection planning where applicable.

Quality, Compliance, and Continuous Improvement

* Own inspection process quality metrics, such as defect escape rates, inspection yield, re-inspection levels, and key rework drivers.

* Lead problem-solving and root-cause analysis (e.g., 5-Why, Fishbone, 8D) for inspection-related quality issues and escapes.

* Drive continuous improvement using Lean, Six Sigma, and mistake-proofing techniques within inspection and NDE processes.

* Ensure compliance with customer requirements, regulatory standards, and internal procedures for inspection and NDE.

* Support new product introduction (NPI), process changes, and industrialization with robust inspection plans and risk assessments.

Leadership, Collaboration, and Training

* Provide day-to-day technical leadership to a team of inspectors, technicians, and inspection engineers.

* Coach and mentor Level 1/2 NDE personnel, metrology technicians, and early-career engineers.

* Champion a strong safety and quality culture, reinforcing adherence to PPE requirements, radiation safety (where applicable), and safe equipment operation.

* Collaborate cross-functionally with Engineering, Manufacturing, Supplier Quality, and Program teams to align inspection strategies with business priorities.

* Represent inspection engineering in customer reviews, MRB boards, and cross-functional investigations.

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Required Qualifications

* Bachelor's Degree accredited college or university in Mechanical Engineering, Materials Engineering, Aerospace Engineering, or a related technical field; or an equivalent combination of education…