Senior Special Processes Engineer & QA Leader in Royston

Company Description

Senior Aerospace Thermal Engineering, located in Royston, UK, is a leading specialist in the manufacture of high-temperature aerospace components, thermal insulation heat shields, and complex fabricated assemblies. As part of Senior plc, the company supplies major global aero-engine and airframe OEMs, with a strong focus on forming hard-to-shape metals such as Titanium and Inconel. SATE's capabilities include advanced hot and cold forming processes - particularly double- and triple-action hot draw forming using six dedicated presses. The business works extensively with high-performance materials including Titanium alloys (Ti 6AL-4V, TA10, TA21), Inconel grades (625, 718), Nimonics, and Jethete to deliver reliable solutions for demanding, high-temperature aerospace applications.

Job Description

Purpose of Role:

The Senior Special Process Engineer serves as the definitive Subject Matter Expert (SME) and technical owner for all special processes at SA Thermal Engineering (SATE), including Non-Conventional Machining, Welding, Chemical Processing, Heat Treatment, and NDT. This role provides strategic and hands-on oversight for the entire process lifecycle: from machine/plant qualification and Nadcap/customer accreditations to operator certification and complex engineering support. As a key member of the Extended Leadership Team, you will drive operational excellence, manage capital improvements, and lead the development of the special process engineering function.

Key Responsibilities:

• Maintenance of all Nadcap and customer special process approvals, including audit accountability, non-conformance management, deviation/concession compilation and implementation of special process improvements.
• Keeping up to date regarding special process requirements, ensuring all internal procedures are aligned with customer and Nadcap requirements.
• Create/implement internal special process audit plans, including the review and disposition of NCR's / findings.
• Lead investigations into high-cost quality non-conformances regarding the special processes and support similar projects within the engineering department.
• Creating, maintaining and approving all internal documentation related to the special processes, e.g. procedures, data sheets, inspection methods.
• Direct involvement in the development of special process control through attendance at Nadcap meetings as a Supplier Task Group member.
• Support the Head of Quality regarding customer quality issues (i.e. NoE's) and take the lead on the resultant problem-solving projects.
• REACH management, including sub-contract processes, and the approval of changes to the special processes where safety concerns are identified.
• Review and approval of all changes for special processes, including disposition of 'return to service' forms regarding maintenance of special process equipment.
• Process owner and key contact for all matters related to special processes, including coordinating with supporting external parties (e.g. NDT level 3) if needed.
• Supporting Quality in process audits - internal, subcontractor, customer and 3rd party (Nadcap), responding to queries on specialist areas of responsibility.
• External Stakeholder management: External level 3 NDT specialist, Nadcap auditors, and customer special process technical subject matter experts.
• Leading and driving continuous improvement initiatives (efficiency, quality) and staying on top of technological evolutions.
• Supporting NPI projects as Special Process lead.
• Advisor to the Material Review Board (MRB) for special process-related topics as required.
• Ensuring that 'best practice' engineering and production techniques are used.
• Leading, managing and developing the Special Process Engineer, overseeing their work activities and performance.
• Provide coaching and mentoring to assist in the development of special process engineers.
• Provide input to strategic, operational and resource planning as part of the extended leadership team.
• Recommend improvements that may require capex approval or be in future budgets and provide supporting financials.
• Deputise for Head of Quality.

Qualifications

Key Requirements:

• Degree/HNC/HND qualified with a background in metallurgy and/or chemical processing.
• Solid understanding of aerospace materials - titanium, nickel alloys, stainless steel, & aluminium.
• Able to quickly interpret and apply engineering, quality and H&S standards.
• Strong understanding of engineering drawings.
• Extensive knowledge of Nadcap requirements (for applicable processes), previous Nadcap audit experience.
• Understanding of Aerospace specifications and approvals - Relating to AS9100 and AS13100.
• Knowledge of aerospace procedures and documentation, including the creation of FAIRs, production permits/concessions, PFMEA's, etc.
• Line management experience desirable.
• Demonstrates a pragmatic approach to problem solving.
• Self-motivated, task orientated, organised with excellent time management skills.
• Engineering-focused with a commercial awareness.
• Strong communication skills (written and verbal).
• Excellent interpersonal skills.
• Computer literate, including MS Office.
• Working knowledge of MRP systems, preferably Syspro.