Senior Quality Engineer

Senior Quality Engineer

BAE Systems, Inc. – Louisville, KY

Full‑time – Mid‑Senior level – Quality Assurance – Defense and Space Manufacturing

Full‑time salary range: $86,460 – $146,982

Employee benefits include health, dental, vision, health savings account, 401(k), disability, life and accident insurance, employee assistance program, legal plan and other perks such as discounts on home, auto and pet insurance. Leave programs include paid time off, paid holidays, paid parental, military, bereavement and applicable federal and state sick leave. Employees may participate in the company recognition program and other incentives based on position level and job specifics.

BAE Systems is seeking a Senior Quality Engineer to support its Louisville, KY site. In this role you will play a critical part in supporting manufacturing and engineering operations by ensuring product and process quality meet rigorous standards. You will focus on identifying and resolving defects, analyzing trends, managing corrective actions, and supporting tiered management systems. You will lead efforts in root cause analysis, containment, and quality system improvement across cross‑functional teams.

• Analyze quality metrics and trends; provide data‑driven insights to support continuous improvement.
• Actively support tiered management systems and structured escalation processes.
• Identify and resolve product and process defects through robust Root Cause and Corrective Action (RCCA), including countermeasure sheets and 5‑Whys.
• Interact and communicate with operators.
• Confirm and reinforce quality requirements.
• Facilitate and participate in Non‑Conformance Report (NCR) preliminary reviews.
• Conduct Measurement System Analysis (MSA) to ensure accuracy and reliability.
• Perform and support containment activities in response to quality issues.
• Manage work packages and support Basis of Estimate (BOE) development for scope planning.
• Support and maintain inspection and control plans.
• Conduct and support internal process audits.
• Respond to Corrective Action Requests (CARs).
• Review technical documents and contractual quality requirements.
• Detect and help define counterfeit part controls.
• Manage and support Process Failure Mode and Effects Analysis (PFMEA) activities.
• Apply GD&T (Geometric Dimensioning and Tolerancing) skills to ensure design integrity.
• Drive ROI‑focused initiatives and continuous quality improvements.

• Bachelor’s degree in Engineering, Quality or a related technical field and four years of experience in a quality engineering role, preferably in aerospace, defense or manufacturing environments, or equivalent.
• Proven experience with Root Cause and Corrective Action, Measurement Systems Analysis, Process Failure Mode and Effects Analysis, and quality audits.
• Experience with Non‑Conformance Report (NCR) preliminary reviews.
• Proficiency in GD&T interpretation and application.
• Familiarity with counterfeit part detection protocols and industry best practices.
• Experience managing work packages and supporting BOE creation.
• Ability to analyze quality metrics and trends and provide data‑driven insights to support continuous improvement.
• Strong communication and collaboration skills to work with cross‑functional teams.
• Computer skills including Microsoft Office and industry‑related software applications.

• ASQ Certification (CQE, CQA, etc.).
• Six Sigma Green Belt or Black Belt.
• Familiarity with BOE processes and tiered support models.
• Previous experience working with DCMA, ISEA or other government agencies.
• Previous experience with SUBSAFE and/or NAVSEA requirements.

BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company delivering a full range of products and services for air, land and naval forces and advanced electronics, security, information technology solutions and customer support services. Improving the future and protecting lives is an ambitious mission, and those who join the company defend national security with breakthrough technology, superior products and intelligence solutions.

Their employees hone their skills on a team that makes a big impact on a global scale.