Staff Engineer, Quality

Primary Duties & Responsibilities

• Partner with Manufacturing, Process Engineering, and R&D teams to improve product quality, process capability, and manufacturing performance
• Spend significant time on the manufacturing floor investigating quality issues, observing processes, and identifying opportunities for improvement
• Develop and implement Statistical Process Control (SPC) methods and process monitoring strategies
• Lead root cause investigations and implement sustainable corrective and preventive actions
• Conduct process capability studies and utilize statistical tools to improve process performance
• Develop and maintain Process Failure Mode and Effects Analyses (PFMEA), Control Plans, and risk mitigation strategies
• Develop statistically sound sampling plans for incoming materials, in-process inspections, and finished products
• Support qualification, inspection, and acceptance activities for Thermadite raw materials and powders
• Evaluate powder characteristics including TPD, particle geometry, morphology, and other critical material attributes
• Develop and improve inspection methods, measurement systems, and metrology techniques
• Support incoming material qualification and supplier approval activities
• Work directly with suppliers to improve material quality, resolve quality issues, and implement corrective actions
• Conduct supplier audits and supplier quality assessments as required
• Support customer quality activities including corrective actions, complaint investigations, and customer communications
• Analyze quality data and communicate trends, risks, and improvement opportunities to leadership and cross-functional teams
• Participate in new product introduction, process transfer, and manufacturing scale-up activities
• Support and maintain the Quality Management System in accordance with applicable standards and procedures

What Success Looks Like

Within the first 12 months, you will:

• Establish robust quality controls for Thermadite materials and manufacturing processes
• Develop effective sampling plans and inspection strategies to support production scale-up
• Improve process capability and reduce quality-related disruptions
• Build productive relationships with manufacturing teams, engineering teams, suppliers, and customers
• Become a trusted technical resource for quality and process-related decisions
• Implement meaningful SPC and process monitoring systems that improve visibility and decision-making
• Lead successful root cause investigations resulting in measurable and sustainable improvements
• Develop a deep understanding of Thermadite materials, manufacturing processes, and quality drivers

Education & Experience

• Bachelor's Degree in Engineering, Quality Engineering, Materials Science, Mechanical Engineering, Chemical Engineering, Manufacturing Engineering, or related technical field
• Minimum 5 years of Quality Engineering experience within a manufacturing environment
• Experience applying SPC, Process Capability Analysis, FMEA, and Six Sigma methodologies
• Experience leading root cause investigations and implementing corrective actions
• Experience working with manufacturing teams in a production environment
• Experience interacting with suppliers and managing supplier quality issues

Preferred

• Experience with powder materials, advanced ceramics, thermal processing, or advanced manufacturing technologies
• Experience with incoming material qualification and supplier development
• Experience with Measurement Systems Analysis (MSA)
• Experience developing sampling plans and inspection strategies
• Experience supporting process transfers and manufacturing scale-up activities
• CQE certification
• Six Sigma Green Belt or Black Belt certification

Skills & Other Requirements

• Strong understanding of quality engineering principles and methodologies
• Working knowledge of SPC, DOE, process capability analysis, sampling plans, and statistical methods
• Strong problem-solving and root cause analysis skills
• Ability to effectively interpret and analyze technical data
• Strong understanding of process control and risk management concepts
• Ability to challenge assumptions and influence decisions through data and technical reasoning
• Excellent communication and interpersonal skills
• Demonstrated ability to achieve results independently and within cross-functional teams
• Strong organizational skills and ability to manage multiple priorities
• Experience with quality management systems and ISO-based manufacturing environments
• Proficiency with Microsoft Office and quality data analysis tools
• Ability to build effective relationships with operators, supervisors, engineers, suppliers, and customers

Working Conditions

This is an in-person position at our Newark, DE site

Office and manufacturing floor environment with regular interaction with production processes, inspection equipment, manufacturing personnel, suppliers, and customers.

Physical Requirements

• Ability to occasionally lift/push/pull up to 25 lbs.
• Able to sit, stand, bend, squat, and walk throughout the facility
• Ability to work safely around manufacturing equipment and…