Quality and Safety Engineer - Thermal Spray

Description

Job Title: Quality and Safety Engineer

Reports to: Quality & Safety Manager, Surface Technologies US

Work Location: Kymera – CASL Houston

FLSA Status: Hourly Non-Exempt

Kymera International is a leading global producer of specialty metal powders, pastes, and granules, catering to industries such as aerospace, defense, automotive, and electronics. Our mission is to drive innovation while adhering to the highest standards of sustainability, operational excellence, and ethical business practices. We are committed to continuous improvement and regulatory compliance on a global scale.

The Quality and Safety Engineer – CASL Houston is a senior-level role responsible for leading quality and safety execution across machining, coating, and thermal spray operations. This position operates at a level above Quality Control Inspector III, with expanded responsibility for quality systems, safety compliance, process improvement, and cross-functional leadership.

The role ensures compliance with company standards, customer specifications, OSHA regulations, and ISO-based Quality Management Systems. It serves as a key driver of continuous improvement, root cause resolution, and audit readiness, while providing technical leadership and mentorship to inspection and production personnel.

• Serve as the Lead Internal Auditor for the CASL Houston facility, managing the full ISO 9001 internal audit life cycle, audit scheduling, pre-audit planning, audit execution, and reporting.
• Provide internal audit support, cross-site auditing, and audit standardization assistance to other Kymera US Surface Technologies manufacturing locations as requested.
• Evaluate Quality Management Systems (QMS) and EHS programs across sites to ensure compliance with customer standards, internal procedures, and regulatory requirements.
• Lead and host external third-party registrar audits (ISO 9001) and customer quality audits at the Houston site, serving as the primary audit point of contact.
• Track, verify, and validate corrective action effectiveness resulting from internal and external audit findings across supported facilities.

• Develop, review, and maintain quality engineering standards, standard operating procedures (SOPs), and quality control plans for machining, grinding, and thermal spray operations.
• Evaluate facility environmental, health, and safety (EHS) risks in Houston; design engineering controls and safety protocols in compliance with OSHA regulations.
• Exercise independent Stop-Work Authority and product containment discretion whenever safety risks or quality non-conformances are identified.
• Manage the site non-conformance system (NCRs), determining technical dispositions (Rework, Scrap, Use-As-Is) in coordination with Engineering and Operations.

• Lead complex root-cause failure investigations for customer returns, internal defects, and safety incidents using 8D, 5-Why, and Fishbone problem-solving tools.
• Design, implement, and validate Corrective and Preventive Action (CAPA) programs to permanently eliminate systemic operational defects.
• Analyze quality and safety data metrics using statistical process control (SPC) techniques to identify defect trends and drive continuous improvement initiatives.

• Establish inspection criteria and metrology standards for visual, dimensional, and metallurgical evaluation of thermal spray coatings and machined components.
• Oversee the site tool calibration system and conduct measurement system analysis (Gauge R&R) to ensure inspection accuracy.
• Provide functional technical leadership, guidance, and mentorship to non-exempt Quality Control Inspectors (Levels I–III).

• Collaborate with Process Engineers, Metallurgists, and Production Managers to optimize thermal spray parameters and resolve manufacturing bottlenecks.
• Prepare comprehensive monthly quality metrics, EHS trends, and audit summaries for executive site and…