Process Engineer

Company Description Quality Aluminum Forge, a SIFCO Industries company, is a manufacturer specializing in aluminum forgings for demanding industrial applications. The company is committed to high-quality production standards, safety, and continuous improvement in its operations. As part of SIFCO Industries, Quality Aluminum Forge benefits from the resources and stability of a larger organization while maintaining a focused manufacturing environment. Team members work in a collaborative setting that values technical expertise, reliability, and accountability. The company offers opportunities to contribute directly to production excellence and process optimization on the shop floor.

Role Description

ESSENTIAL FUNCTIONS: (But not limited to the following)

Compliance & Gap Analysis

• Conduct comprehensive gap assessments of manufacturing processes against:
• NADCAP requirements (AC7102, AC7102/5, AC7102/8, AC7102/9, AC7102S, etc.)
• AMS specifications
• Customer-specific requirements including Boeing, Collins Aerospace, Lockheed Martin, Bell Helicopter, Honeywell, Parker, and GKN.
• AS9100 Quality Management System requirements.
• Review procedures, work instructions, forms, records, and process controls to identify compliance deficiencies.
• Develop and maintain compliance matrices correlating process requirements to internal procedures and records.
• Lead closure of audit findings, corrective actions, and preventive actions.

Process Improvement

• Analyze manufacturing workflows to identify inefficiencies, risks, and compliance gaps.
• Recommend and implement process improvements that enhance quality, productivity, and compliance.
• Utilize Lean Manufacturing, Six Sigma, and Root Cause Analysis methodologies to improve process performance.
• Monitor process capability and ensure process controls remain effective and compliant.

Audit Readiness & Support

• Serve as a primary resource during NADCAP, customer, and regulatory audits.
• Conduct internal process audits and mock assessments.
• Lead preparation activities for accreditation and customer audits.
• Review audit findings and coordinate effective corrective action plans.
• Ensure objective evidence is maintained and readily available for audits.

Technical Documentation

• Develop, revise, and maintain:
• Standard Operating Procedures (SOPs)
• Work Instructions (WIs)
• Process Flow Diagrams
• Control Plans
• Risk Assessments
• Process Validation Reports
• Ensure all documentation aligns with applicable aerospace requirements and customer specifications.

Customer & Regulatory Requirements Management

• Interpret customer specifications, purchase order requirements, and engineering standards.
• Assess impact of specification revisions and communicate changes throughout the organization.
• Develop implementation plans for new customers and regulatory requirements.
• Ensure process controls support compliance with customer flow-down requirements.

Cross-Functional Collaboration

• Partner with Quality, Manufacturing, Maintenance, Heat Treat, and Engineering teams to resolve compliance issues.
• Provide technical guidance regarding process controls, specifications, and accreditation requirements.
• Support training initiatives related to NADCAP and customer-specific requirements.

Data Analysis & Reporting

• Analyze process performance data and identify trends.
• Prepare reports summarizing compliance status, audit readiness, and improvement opportunities.
• Develop metrics and dashboards to track compliance and process effectiveness.

QUALIFICATIONS:

Education

• Bachelor's Degree in Engineering (Manufacturing, Mechanical, Industrial, Materials, Aerospace, or related field).
• Master's Degree preferred.

Experience

• Minimum 5 years of experience in aerospace manufacturing.
• Minimum 3 years of experience supporting NADCAP-accredited processes.
• Continuous Improvement experience.
• Experience in aluminum forging, heat treating, machining, or special processes preferred.
• Proven experience conducting gap analyses and implementing corrective actions.
• Experience supporting customer and third-party audits.

Technical Knowledge

• Strong knowledge of:
• NADCAP accreditation requirements
• AS9100D
• AMS specifications
• Aerospace quality systems
• Statistical process control (SPC)
• Root Cause Corrective Action (RCCA)
• FMEA and Risk Management
• Continuous Improvement methodologies

Preferred Knowledge

• Aerospace aluminum forging processes.
• Heat Treating (AMS2750, pyrometry, hardness, conductivity testing).
• Metallurgical testing and process validation.
• Boeing, Lockheed Martin, Collins Aerospace, Honeywell, and GKN quality requirements.

Skills & Competencies

• Strong analytical and problem-solving skills.
• Excellent technical writing and documentation abilities.
• Ability to interpret complex specifications and standards.
• Effective project management and organizational skills.
• Strong communication and presentation skills.
• Ability to lead cross-functional teams.
• Detail-oriented with a focus on compliance and continuous improvement.
• Proficient in Microsoft Office Suite and quality management software.

Key Performance Indicators (KPIs)

• Reduction in identified compliance gaps.
• Successful NADCAP and customer audit outcomes.
• On-time closure of corrective actions.
• Improvement in process capability metrics.
• Reduction in repeat audit findings.
• Compliance matrix completion and maintenance.
• Internal audit effectiveness and closure rates.
• Successful implementation of customer specification changes.

Preferred Certifications

• ASQ Certified Quality Engineer (CQE)
• ASQ Certified Manager of Quality/Organizational Excellence (CMQ/OE)
• NADCAP Internal Auditor Training
• Lean Six Sigma Green Belt or Black Belt
• Certified Aerospace Auditor (CAA)

LANGUAGE SKILLS

Ability to read, analyze and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to write reports, business correspondence and policies and procedures. Ability to effectively present information and respond to questions from employees, managers, and outside service providers.

MATHEMATICAL SKILLS

Ability to apply basic to moderate mathematical concepts such as sums and averages. Ability to create graphs and charts.

REASONING ABILITY

Ability to define problems, collect data, establish facts and draw valid conclusions.

PHYSICAL DEMANDS

• Ability to work in both office and manufacturing environments.
• Ability to walk production areas and inspect manufacturing processes.
• Ability to review technical documents and manufacturing records.
• Occasional lifting up to 25 pounds.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is occasionally exposed to fumes or airborne particles and vibration. The noise level in the work environment is moderate. The role requires a presence on the shop floor for up to 30% of the day be effective.