Senior Build Reliability Engineer

Senior Build Reliability Engineer at Castelion

About Castelion

Castelion is bringing a new approach to defense development and production: one that focuses on short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production  design, build, and test next generation weapon systems to give America and its Allies a definitive edge in defense capabilities.

Senior Build Reliability Engineer

The Senior Build Reliability Engineer will lead initiatives aimed at continuous improvement in the reliability and quality of our products. You will develop and implement internal processes and manufacturing software to optimize development and production workflows and ensure high-quality output. You will guide teams in conducting reliability assessments, implementing preventative measures, and addressing quality issues through root cause analyses and corrective actions, all while ensuring compliance with industry standards and regulatory requirements.

Responsibilities

Design and Manufacturing

• Work closely with design, manufacturing, and operations teams to ensure reliability and quality considerations are integrated into all phases of the product lifecycle.
• Participate in Design and Build Reviews to ensure design for manufacturability and inspectability.
• Reviews and approves Process Plans, specifications, and build documentation for completeness, accuracy, regulatory compliance, and quality objectives.
• Support the development and implementation of internal processes and manufacturing software to optimize production efficiency, product quality, and change control.
• Facilitate the engineering change control process (ECR/ECO) with a focus on traceability and impact alignment to maintain clean configuration genealogy.

Inspection and Test Process

• Ensure appropriate test validation methods and inspection techniques have been considered to validate design and manufacturing processes.
• Develop and implement Quality Control Processes, and Standards, and Planning, ensuring compliance with internal and external standards and regulations.
• Design or procure new measurement equipment as required to achieve required inspections with maximum efficiency.
• Validate measurement and test methods using process capability and measurement systems analysis (MSA) statistical tools. Propose solutions to remove the need to verify product conformance through measurement, e.g. poka-yoke.

Evaluates and analyzes production quality landscape

• Utilize reliability and quality data to generate reports, identify trends, and recommend improvements to enhance product and process reliability and performance.
• Use data to make landscape transparent and drive project prioritization. Responsible for ensuring that issues related to product reliability are primary focus.
• Drive achievement of quality targets through a review hierarchy with appropriate levels of management.

Corrective Action Preventive Action

• Utilize reliability and quality data to generate reports, identify trends, and recommend improvements to enhance product and process reliability and performance.
• Leverage tools like FMEA and statistical analysis to identify and prevent quality and reliability issues.
• Lead, facilitate, and participate in root cause investigations and ensure appropriate action to prevent recurrence.

Nonconformance Management

• Support review of all nonconformance conditions for adequate resolution and rationale prior to closure.
• Lead containment functions to include impact and risk analysis.
• Oversee control of all non-conforming hardware.

Compliance and Training

• Support efforts to implement and adhere to Quality Management System policies and other regulatory requirements.
• Facilitate creation of training plans and materials for technician and inspector competency.
• Develop training materials and provide support to end-users to ensure effective utilization of manufacturing and management system software.
• Drive continuous improvement initiatives aimed at enhancing product reliability and risk mitigation.

Requirements and Skills

• Minimum 4+ years in reliability and/or quality engineering role.

Preferred Qualifications

• Experience in aerospace or…