Special Process Engineer - NADCAP

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.