Special Process Engineer - NADCAP

STS Aerospace is a global leader in designing, manufacturing, and supplying high-performance components and systems for the aerospace industry. Our expertise lies in fluid transfer systems, hoses, ducting, and other critical components that ensure safety, reliability, and efficiency in both commercial and defense aviation sectors. With a commitment to excellence and innovation, we deliver engineering solutions that meet the stringent demands of aerospace standards, supporting our clients in achieving operational success worldwide.

Primary Responsibilities

• Maintain and ensure continuous compliance with NADCAP requirements for Fluid Distribution Systems (FDS) and Welding special processes.
• Develop, implement, and maintain special process procedures, work instructions, and control plans in line with NADCAP, AS9100, and customer requirements.
• Ensure proper implementation and control of welding processes, including procedure qualifications (WPS/PQR), welder qualifications, and process validations.
• Ensure compliance of FDS processes, including cleanliness control, contamination prevention, pressure testing, assembly, and handling requirements.
• Plan, support, and execute NADCAP audits (initial, surveillance, and re‑accreditation) for FDS and Welding.
• Act as process owner for assigned special processes and ensure day‑to‑day compliance on the shop floor.
• Conduct process risk assessments and ensure adequacy of controls through PFMEA and Control Plans.
• Identify gaps during audits or internal reviews and implement root cause analysis and permanent corrective actions.
• Monitor process performance metrics and ensure process capability, repeatability, and stability where applicable.
• Coordinate with Quality, Production, and Engineering teams to ensure process discipline and compliance.
• Ensure calibration, validation, and maintenance of special process equipment, tooling, and fixtures.
• Maintain traceability of materials, consumables, parameters, and process records as required by NADCAP.
• Support customer audits and regulatory assessments related to special processes.
• PRI Activities handling and implementation.

Additional Duties

• Conduct internal NADCAP self‑audits and layered process audits for FDS and Welding.
• Drive continuous improvement initiatives related to yield, defects, rework, and audit findings.
• Support training and qualification of operators, welders, inspectors, and technicians on special process requirements.
• Ensure availability and control of approved procedures, specifications, and revision‑controlled documents.
• Support investigation of process deviations, escapes, and non‑conformances related to special processes.
• Coordinate with external suppliers for NADCAP‑approved special process outsourcing, as applicable.
• Provide backup support for fellow Special Process / Quality engineers when required.

• Bachelor’s Degree in Engineering (Mechanical, Metallurgical, Aerospace, or equivalent).
• 5–8 years of experience in Aerospace Special Processes, preferably FDS and Welding.
• Strong working knowledge of NADCAP (Welding) and applicable FDS checklists, along with AS9100.
• Hands‑on experience with Welding processes, procedure qualification, parameter control, and inspection methods.
• Strong understanding of FDS requirements, including cleanliness, contamination control, pressure testing, and assembly practices.
• Experience in NADCAP audit preparation, closure of non‑conformances, and sustaining accreditation.
• Proficiency in Root Cause Analysis, 8D, PFMEA, SPC, and corrective action methodologies.
• Ability to interpret customer specifications, aerospace standards, and regulatory requirements.
• Strong analytical, documentation, and problem‑solving skills.
• Effective communication and coordination skills for working with internal teams and external auditors.
• Proficient in Microsoft Office (Excel, Word, PowerPoint)

www.stsaero.com

We believe that different perspectives and backgrounds are what make a company flourish. All qualified applicants will receive equal consideration for employment regardless of color, religion, sex, sexual orientation, gender identity, national origin, economic status, disability, age, or any other legally protected characteristics. We are proud to be an inclusive company with values grounded in equality and ethics, where we celebrate, support, and embrace diversity.

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