Senior Quality Engineer - Machining

Senior Quality Engineer

BAE Systems, a leading defense contractor and a Top 10 Prime Contractor to the Department of War, is seeking a Senior Quality Engineer to join our Naval weapon systems team in Louisville, Kentucky. At BAE Systems, we value our workforce and their well-being. We prioritize safety, offer generous benefits, and promote work life balance, like a 9/80 schedule with every other Friday off. The Senior Quality Engineer plays a critical role in supporting machining and engineering operations by ensuring product and process quality meet rigorous standards. This role focuses on identifying and resolving defects, analyzing trends, managing corrective actions, and supporting tiered management systems. The Senior QE will lead efforts in root cause analysis, containment, and quality system improvement across cross-functional teams. As a Quality Engineer, you will:

• Analyze quality metrics and trends; provide data-driven insights to support continuous improvement.
• Actively support tiered management systems and structured escalation processes.
• Identify and resolve product and process defects through robust Root Cause and Corrective Action (RCCA), including countermeasure sheets and 5-Whys.
• Interact and communicate with operators.
• Confirm and reinforce quality requirements.
• Facilitate and participate in Non-Conformance Report (NCR) preliminary reviews.
• Conduct Measurement System Analysis (MSA) to ensure accuracy and reliability.
• Perform and support containment activities in response to quality issues.
• Manage work packages and support Basis of Estimate (BOE) development for scope planning.
• Support and maintain inspection and control plans.
• Conduct and support internal process audits.
• Respond to Corrective Action Requests (CARs).
• Review technical documents and contractual quality requirements.
• Detect and help define counterfeit part controls.
• Manage and support Process Failure Mode and Effects Analysis (PFMEA) activities.
• Apply GD&T (Geometric Dimensioning and Tolerancing) skills to ensure design integrity.
• Drive ROI-focused initiatives and continuous quality improvements.

Required Education, Experience, & Skills:

• Typically a Bachelor’s Degree in Engineering, Quality, or related technical field. We will consider additional relevant experience in lieu of degree.
• Minimum of 4 years in a quality engineering role, preferably in aerospace, defense, or manufacturing environments.
• Proven experience with RCCA and PFMEA.
• Strong communication and collaboration skills with cross-functional teams.
• Proficiency in GD&T interpretation and application.
• Experience managing work packages and supporting BOE creation.

Preferred Education, Experience, & Skills:

• ASQ Certification (CQE, CQA, etc.).
• Six Sigma Green Belt or Black Belt.
• MSA and quality audits.
• Familiarity with Phoenix BOE processes and tiered support models.
• Familiarity with counterfeit part detection protocols and industry best practices.

Pay Information:

Full-Time Salary Range: $88189 - $149922. Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience. Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20 hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.

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