Senior Special Process Engineer

Location: Royston, Hertfordshire, gb

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