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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
Job Title: Senior Special Process Engineer
Reporting to: Head of Quality
Direct Reports: Special Process Engineer
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
Company Statement
This job description is not intended to establish a total definition of a job but to outline duties. This job description will be amended at the discretion of management.
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, & aluminum
- 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
Additional Information
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