Quality Assurance Manager

Quality Assurance & Control (QA/QC) — Explosives Production

Job Title

Quality Assurance Specialists

Department

Production

Reports To

Head of Production

Location

Ballinger, TX

Travel

Occasional ( 10%), including customer, subcontractor, and government-site visits

Position Summary

The QA/QC professional serves as the gatekeeper of product standards within an explosives manufacturing operation. Quality Assurance (QA) builds the systems and processes that prevent defects before they occur, including audits, Standard Operating Procedures (SOPs), certifications, and data packages. Quality Control (QC) performs hands-on testing, sampling, and inspection at defined stages of production to verify that materials, in-process product, and finished goods conform to specification. Together, QA and QC manage product release, ensure regulatory and contractual compliance, and drive continuous improvement using Lean Six Sigma (LSS) and related methodologies, all within the heightened safety and security context of energetic materials manufacturing.

Essential Duties & Responsibilities

• Quality Assurance (Systems & Prevention)

• Plan and conduct internal audits of production, laboratory, and storage/magazine areas; track findings through corrective and preventive action (CAPA) closure.

• Support and host external/regulatory audits and customer quality surveillance visits.

• Maintain the quality management system (QMS) documentation hierarchy and change-control/document-control processes.

• Compile and issue certificates of analysis/conformance (CoA/CoC) and finished-goods data packages for product release and shipment.

• Own and maintain calibration, preventive maintenance, and gauge R&R programs for inspection and test equipment.

• Lead or support root-cause analysis for nonconformances, customer complaints, and process deviations.

• Track quality metrics (yield, scrap/rework, first-pass yield, complaint rate, CAPA aging) and report trends to leadership.

• Champion Lean Six Sigma and continuous-improvement projects; facilitate kaizen events and control-plan updates.

• Support new product introduction, process validation (IQ/OQ/PQ), and first-article inspection activities.

• Maintain training records and administer quality-related training and certification programs for production and lab personnel.

• Quality Control (Hands-On Testing & Inspection)

• Perform incoming inspection and testing of raw materials and components against approved specifications.

• Conduct in-process inspections and sampling at designated hold points throughout production per approved sampling plans (e.g., customer-specified plans).

• Execute physical, chemical, and functional testing per approved test methods, recording results in the ERP/MRP or paper batch record.

• Perform final inspection, lot acceptance testing, and disposition (accept/reject/hold) of finished product prior to release.

• Segregate, tag, and control nonconforming material per the material review board (MRB) process.

• Maintain accurate, legible, and complete batch records, inspection logs, and chain-of-custody documentation.

• Operate and maintain laboratory and inspection equipment; perform routine calibration checks and equipment verification.

• Support environmental, safety, and process-safety monitoring tasks that intersect with quality (e.g., moisture content, density, sensitivity screening) as required by site procedures, without disclosing or handling classified or export-controlled formulation data outside authorized scope.

• Regulatory, Safety & Compliance

• Support compliance with applicable federal, state, and local regulations governing explosives manufacturing (e.g., ATF licensing/recordkeeping, DOT/PHMSA transportation classification, OSHA Process Safety Management, and applicable military/customer specifications such as MIL-STD or AQAP where relevant).

• Maintain lot traceability and recordkeeping required for regulatory reporting and product recall/traceback capability.

• Participate in process hazard analyses (PHA) and management-of-change (MOC) reviews from a quality/compliance perspective.

• Adhere strictly to site security, access control, and handling procedures for regulated and hazardous materials.

Supervisory Responsibilities

Level-dependent. May include leading a small team of QC inspectors/technicians, assigning daily testing/inspection workload, and reviewing work for accuracy and completeness. Senior/Manager-level roles may carry direct supervisory authority over QA/QC staff.

Qualifications

Education & Experience

• Bachelor's degree in Chemistry, Chemical Engineering, Materials Science, Industrial Engineering, or related field preferred; equivalent combination of education and experience considered.

• 2–5 years of experience in quality assurance/quality control, preferably within explosives, propellants, munitions, chemical processing, or another highly regulated manufacturing environment (years scale with level).

• Experience with ISO 9001 and/or AS9100 quality systems; energetics-specific standards (e.g., MIL-STD-1916, AQAP-2110/2130) a plus.

• Lean Six Sigma certification (Yellow/Green/Black Belt) preferred.

Knowledge, Skills & Abilities

• Working knowledge of statistical process control (SPC), sampling plans, and measurement systems analysis.

• Strong root-cause analysis and problem-solving skills.

• Proficiency with quality/LIMS software, ERP/MES systems, and standard office software; data analysis tools (Minitab, Excel) a plus.

• Excellent written communication for SOPs, audit reports, and data packages.

• High attention to detail and unwavering commitment to data integrity, given the safety-critical nature of the product.

• Ability to read and interpret engineering drawings, specifications, and test methods.

• Ability to obtain and maintain any required background clearance/authorization for handling regulated materials.

Certifications & Licensing (as applicable)

• ASQ Certified Quality Technician/Engineer/Auditor (CQT/CQE/CQA) preferred.

• Ability to pass background checks required for ATF-licensed explosives manufacturing facilities.

• Site-specific hazardous materials handling and process safety training (provided post-hire).

Physical Demands & Work Environment

• Regularly required to stand, walk, bend, and use hands for equipment operation and sample handling.

• Ability to wear required personal protective equipment (PPE), including flame-resistant clothing, safety glasses, and hearing protection, for extended periods.

• Occasional lifting up to 25–50 lbs (samples, containers, equipment).

• Work is performed in and around active production and magazine/storage areas subject to strict safety, security, and static-control protocols.

• Exposure to noise, chemical odors, and controlled quantities of energetic materials under strict engineering and administrative controls; adherence to all site safety rules is mandatory.

• May require work in a controlled-access facility with restrictions on personal electronic devices.

Key Performance Measures

• On-time product release / cycle time from final test to disposition.

• First-pass yield and nonconformance/scrap rate.

• CAPA closure rate and average closure time.

• Audit finding trends (internal and external).

• Customer complaint rate and corrective-action effectiveness.

• Calibration/PM compliance rate.