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

Additional Duties

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

• Bachelor’s Degree in Engineering (Mechanical, Metallurgical, Aerospace, or equivalent).
• 5–8 years of experience inAerospace Special Processes, preferablyFDS and Welding.
• Strong working knowledge ofNADCAP (Welding) and applicableFDS checklists, along withAS9100.
• Hands‑on experience withWelding processes, procedure qualification, parameter control, and inspection methods.
• Strong understanding ofFDS requirements, including cleanliness, contamination control, pressure testing, and assembly practices.
• Experience inNADCAP audit preparation, closure of non‑conformances, and sustaining accreditation.
• Proficiency inRoot Cause Analysis, 8D, PFMEA, SPC, and corrective action methodologies.
• Ability to interpretcustomer specifications, aerospace standards, and regulatory requirements.
• Stronganalytical, documentation, and problem‑solving skills.
• Effectivecommunication and coordination skills for working with internal teams and external auditors.
• Proficient inMicrosoft 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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