Location: This role is based onsite at our office in Louisville, COTravel: Up to 20%
Job ID: 571

The Role

As a Senior Staff Quality Engineer, you will serve as the primary technical authority for quality excellence across our spacecraft structural and propulsion systems. This is a high-impact leadership role designed for an expert who thrives at the intersection of complex aerospace manufacturing and rigorous mission assurance. You won't just be checking boxes; you will be architecting the framework that ensures our hardware survives the harshest environments-and works as expected!

You will act as a strategic partner to Hardware Engineering, Manufacturing, and Systems Engineering, moving beyond standard inspection to implement robust Process Failure Mode and Effects Analysis (PFMEA), advanced Root Cause Corrective Action (RCCA), and scalable quality processes. Your influence will span the entire product lifecycle-from design for manufacturability to final on-orbit readiness-ensuring every component meets the uncompromising standards of AS9100 and ITAR compliance.

Responsibilities

• Develop and enforce quality requirements for spacecraft structural assemblies, subassemblies, including propulsion systems, and components. Familiarity with RF SMT test or manufacturing experience (Radio Frequency Surface-mount technology) is a plus.
• Lead, facilitate, and investigate nonconformances with root cause corrective action (RCCA) methodologies (such as 8D, DMAIC, and other structured problem-solving methods). Analysis of NCRs, trends, supplier projects, and internal processes.
• Provide real-time quality support on the manufacturing floor, including developing inspection test procedures, acceptance test procedures (ATP) and overseeing environmental testing quality compliance (vibration, thermal vacuum, EMI/EMC).
• Develop in-process inspection criteria, First Article Inspection plans, and final product acceptance protocols.
• Develop, manage, and support MRB (Material Review Board) dispositions and oversee rework/ repair activities.
• Implement incoming inspection process for hardware and materials, and review supplier quality escape reports.
• Collaborate with Systems Engineering to verify that critical-to-quality (CTQ) features are flowed down and verified at build stages.
• Support internal and external audits, including customer and certification audits.
• Manage supplier quality assurance activities for aerospace parts and assemblies.
• Support manufacturing readiness activities including PFMEA (Process Failure Mode and Effects Analysis) and Control Plans.
• Maintain calibration, gaging, and special process control systems in compliance with aerospace standards.
• Train operators and inspectors on inspection methods, specifications, and quality requirements.
• Ensure compliance with contractual quality requirements, ITAR regulations, and ISO/ AS9100 standards.
• Support failure investigations and anomaly resolutions for hardware issues.
• Familiar with tracking and reporting supplier performance metrics (OTD, PPM, NCR rates).
• Maintain strict configuration management and traceability of materials, processes, and documentation per standards.
• Review engineering drawings, specifications, and process plans to ensure quality requirements are defined and met.
• Partner with Manufacturing Engineering to develop robust process controls and inspection plans.
• Support design for manufacturability and producibility reviews to ensure quality is built into critical spaceflight hardware.
• Monitor and control special processes (e.g. bonding, welding, soldering) critical to spaceflight qualification.
• Support design reviews, test readiness reviews, and customer acceptance milestones.
• Conduct supplier audits, PPAP reviews, First Article Inspections (FAIs) per AS9102 standards.

Requirements

• B.S. or higher in Engineering (Mechanical, Electrical, Aerospace, Systems, or Industrial)
• 13+ years of experience in a regulated industry (aerospace, robotics, medical device, automotive, or equivalent)
• Deep familiarity with MES (Manufacturing Execution Systems) and AS9102 standards.
• To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), Capella Employees must be a U.S. citizen, lawful U.S. permanent resident (i.e., current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum, or be eligible to obtain the required authorizations from the U.S. Department of State and/or the U.S. Department of Commerce, as applicable. Learn more about ITAR here.

Preferred Qualifications

• ASQ certifications (CQE, CRE, CMQ/OE) are highly preferred.
• Certified Lean Six Sigma Black Belt with a proven track record of using statistical methods (DOE, SPC, ANOVA) to reduce variability in low-volume, high-complexity manufacturing.
• A history of mentoring mid-level engineers and developing internal training curricula that raised the overall "Quality IQ" of a production team.

Compensation

The approximate base salary range for this position is $186100 - $218,659. The total compensation package includes base salary, bonus, equity, and a range of benefits available on our career site.

Benefits/Perks

In addition to an opportunity to take part in an innovative, collaborative and fast-growing business with a highly motivated and skilled team, we also take pride in taking care of our employees. Here are just a few ways that we show our appreciation:

• We provide extensive medical coverage, including strong vision and dental plans, flexible spending accounts, and additional supplemental health options.
• Stock option grants for new hires
• 401K Plan to invest in your long-term retirement goals
• Generous Parental Leave
• Paid Flexible Time Off Policy
• Lifestyle Spending Account
• Commuter & Parking Benefits
• Mental Health Resources
• Monthly Phone Stipend
• Daily provided lunches and stocked kitchens.
• Furry friends? We've got you covered with dog-friendly work environment & them with pet insurance options