Quality Assurance & Product Verification Specialist

Role Summary

We are looking for a professional who can define and demonstrate the difference between an avionics board being “manufactured” and being “acceptable.” You will establish acceptance criteria, prepare inspection and test plans, lead AS9102 First Article Inspection (FAI) activities, follow nonconformities through to their root causes, and represent the company during AS9100/AQAP audits.

Key Responsibilities

Acceptance Criteria and Inspection Infrastructure

• Prepare an Inspection and Test Plan (ITP) for each board, defining Incoming Quality Control (IQC), In-Process Quality Control (IPQC), and Final/Outgoing Quality Control (FQC/OQC) checkpoints, sampling plans (ANSI/ASQ Z1.4), and record formats. 
• Adapt the acceptance criteria of IPC-A-610 Class 3 (including the Space Addendum where required), IPC J-STD-001 Class 3, IPC-A-600 / IPC-6012 Class 3-3A, and IPC/WHMA-A-620 Class 3 to the production environment, and establish decision trees for borderline conditions. 
• Establish visual inspection stations: magnification levels, lighting, microscopes, and X-ray image evaluation criteria (BGA void limits, head-in-pillow, hole fill). 
• Define verification criteria for conformal coating, staking, potting, and cleaning processes (IPC-CC-830, UV inspection, thickness measurement, ROSE/ion chromatography limits). 
• Operator qualification: Maintain IPC training and certification matrices, eye examination records, hand-soldering and rework authorization records, and requalification intervals. 

Product Verification and Validation

• Prepare and approve AS9102 First Article Inspection (FAI) packages: ballooned drawings, Forms 1/2/3, measurement records, material certificates, and special-process certifications. 
• Manage the AS9145 / APQP-PPAP process, including PFMEA, Control Plans, MSA, and process capability (Cp/Cpk) studies. 
• Identify Key Characteristics (KC) and manage process variation in accordance with AS9103. 
• Qualify fixtures, test equipment, and measurement systems: golden sample correlation, Gage R&R, false-reject/false-accept analysis, and approval of acceptance reports. 
• Manage the measurement and test equipment calibration program: inventory, calibration intervals, traceable calibration through accredited laboratories, and retrospective impact analysis when deviations are identified. 
• Manage sample control for DO-160G / MIL-STD-810 qualification tests, including pre- and post-test inspections and acceptance of test reports; verify ESS profiles from a quality perspective. 

Nonconformity and Continuous Improvement

• Lead Nonconformance (NCR) management and chair the Material Review Board (MRB): formally document use-as-is, rework, repair, deviation, and scrap dispositions. 
• Manage the deviation and waiver process and obtain customer and/or authority approval where required. 
• Lead 8D / CAPA activities, including root-cause analysis (5 Why, Ishikawa, Fault Tree Analysis), effectiveness verification, and closure of recurring nonconformities. 
• Perform SPC and quality data analysis: FPY, DPMO, Pareto analysis, trend monitoring, and publication of the quality dashboard. 
• Analyze field returns (RMA), determine whether root causes are related to design, process, or suppliers, and provide feedback to R&D. 
• Calculate Cost of Poor Quality (COPQ) and lead cost-reduction initiatives. 

Quality System, Suppliers, and Audits

• Implement product-related requirements of the AS9100 / EN9100 (and, where applicable, AQAP-2110/2310) quality management system; establish procedures and forms/records infrastructure. 
• Manage the internal audit program; represent the company during customer, SSB, and certification-body audits and ensure closure of findings. 
• Supplier quality: Conduct pre-approval evaluations, second-party audits (EMS, bare PCBs, wiring/harnesses, special processes), supplier FAI and certificate (CoC/CoA) verification, and supplier corrective action (SCAR) follow-up. 
• Implement counterfeit-part prevention controls in accordance with AS5553 / AS6081, including inspection, quarantine, and reporting processes for suspect parts. 
• Conduct periodic audits of ESD (ANSI/ESD S20.20) and FOD (AS9146) programs and maintain measurement/monitoring records. 
• Verify traceability: lot/date code → work order → serial number chain and as-built configuration records. 
• Assess the quality impact of ECO/ECNs and determine acceptance criteria changes and whether a repeat FAI (delta FAI) is required during revision transitions. 

Required Qualifications

• Bachelor’s degree in Electrical-Electronics Engineering / Electronics & Communication Engineering / Mechatronics / Metallurgical & Materials Engineering / Industrial Engineering. Relevant associate-degree candidates with strong practical experience may also be considered. 
• At least 4 years of quality experience in an organization manufacturing electronic boards (PCBA). 
• Practical proficiency in IPC-A-610 Class 3 and IPC J-STD-001 acceptance criteria, with the ability to defend decisions on borderline conditions by referencing the applicable standards. 
• Knowledge of SMD component handling and the SMT process: component packages and marking identification, polarity, reel/lot/date-code traceability, MSL / J-STD-033 practices, and recognition of reflow-related defect types. 
• Ability to interpret technical data: schematics, assembly drawings, BOMs, Gerber/ODB++, work instructions, datasheets, and test reports. 
• Experience working in an AS9100 / EN9100 environment and strong understanding of procedures, records, and audit practices. 
• Practical experience in nonconformity management, 8D / CAPA, and root-cause analysis. 
• Practical knowledge of metrology and measurement: calipers, micrometers, stereo microscopes, thickness gauges, and calibration management. 
• Technical English: able to read and apply standards and datasheets and conduct technical correspondence. 
• For male candidates, completion of military service is required. 

Preferred Qualifications

• IPC certifications: IPC-A-610 CIS or CIT (Instructor), IPC J-STD-001 Specialist/Trainer, IPC/WHMA-A-620 CIS/CIT — candidates holding CIT certification will be given priority due to the ability to provide internal training. 
• AS9100 / EN9100 Internal Auditor or Lead Auditor certification; AQAP-2110/2310 experience. 
• Experience preparing AS9102 FAI packages and obtaining customer approval. 
• Experience with AS9145 / APQP-PPAP, PFMEA, and Control Plan development. 
• Aerospace/defense industry experience; product verification experience under DO-254 / DO-160 / MIL-STD-810 / MIL-STD-461. 
• Six Sigma Green Belt / Black Belt; experience using Minitab or JMP for SPC and MSA. 
• Training or practical experience in counterfeit-part detection under AS5553 / AS6081 / IDEA-STD-1010. 
• Experience with X-ray (AXI) image evaluation and BGA void analysis. 
• Second-party supplier audit experience; familiarity with NADCAP special processes. 
• ESD coordinator experience (S20.20) and FOD program experience. 
• Cable/harness quality control, crimp pull testing, and cross-section evaluation experience.