AIRCRAFT INSPECTOR JOB DESCRIPTION

When an aircraft inspector's findings go undocumented, or inspection steps are skipped, nonconforming parts reach final assembly, and DCMA holds become costly program delays. The Aircraft Inspector owns the verification checkpoint between production work and accepted output. Working within AS9100-governed quality systems, this role applies close-tolerance dimensional measurement and systems inspection across airframes, assemblies, and ground handling operations. Government contract environments demand a standard of rigor here that few other manufacturing roles require.

As the Aircraft Inspector, you verify that composite structures, mechanical assemblies, and aircraft systems meet written specifications and regulatory requirements before product advances or is released, directly protecting airworthiness and program compliance. You operate within a quality assurance organization that interfaces with government representatives, subcontractors, and production personnel across active modification and maintenance programs.

Career Impact: Qualifying at the Aircraft Inspector level in a DCMA-interfacing program builds documented government-contract inspection credentials that carry significant weight across the defense aerospace labor market.

Business Impact: Every accept-or-reject decision this role makes determines whether an aircraft advances toward mission-readiness or returns to production, making inspection accuracy a direct driver of schedule and contract performance.

Growth Opportunity: Inspectors who develop proficiency across composite, hydraulic, and electrical systems, and gain experience leading corrective action processes are positioned to advance into Quality Inspector Lead or Quality Management System Auditor roles.

• Inspect composite parts, mechanical assemblies, and completed aircraft systems against written specifications and blueprint packages to verify conformance.
• Perform close-tolerance dimensional checks using precision instruments across in-process and final-assembly work.
• Review and execute inspection checklists and work instructions to document accept-or-reject decisions on each inspected product.
• Monitor ground handling operations and in-progress work to identify nonconformances before they advance downstream.
• Conduct kitting inspections and verify installation completeness of hydraulic, pneumatic, electrical, and fuel system assemblies.
• Coordinate with production personnel and subcontractors to resolve quality-related findings and document corrective actions.
• Support internal audits of manufacturing and modification processes to maintain Quality Management System compliance.
• Maintain accurate inspection logs and produce written reports that support government customer and DCMA review.

• Bachelor's degree in aviation technology, quality systems, or a related field, or equivalent work experience.
• 4 or more years of hands-on aircraft maintenance or QA inspection experience, with demonstrated work on fixed-wing or rotary-wing airframes.
• Working knowledge of AS9100 quality management standards and government contract inspection requirements, including DCMA program interface.
• Proficiency in reading and interpreting engineering blueprints, technical specifications, and drawing packages.
• Demonstrated ability to operate precision measurement instruments, including micrometers, calipers, depth gauges, and radius gauges.
• Familiarity with Root Cause Corrective Action processes and their application to production nonconformances.
• Ability to perform physically demanding work, including lifting to 50 pounds, working overhead, and sustained standing or kneeling.
• Ability to work flexible or rotating shift schedules in an active production or MRO environment.

• Active DoD Secret Clearance or eligibility to obtain one, reflecting prior government program experience.
• USAF maintenance certification at Level 5 or above, or equivalent military aviation inspection qualification.
• Experience in presenting inspected products to DCMA representatives and managing formal hold resolution processes.
• Certification or documented proficiency in half- and full-face respirator use within a composites or sealant-handling environment.

• Accept/reject decision accuracy rate, measured against downstream nonconformance and rework findings traced to prior inspection.
• First-pass inspection completion rate per shift, reflecting how consistently work advances without re-inspection loops.
• DCMA holds count per program period, tracking how often government representatives flag discrepancies in released products.
• Corrective action closure rate within defined timeframes, measuring responsiveness to documented nonconformances.
• Inspection log completeness score, reflecting audit-ready documentation of all inspection outcomes and findings.
• Typical tools: precision dimensional measurement (commonly micrometers, calipers, depth and radius gauges); inspection documentation systems (commonly Manufacturing Execution System platforms)

• Base Salary Range: $58,000 to $82,000 annually, depending on experience and clearance status
• Bonus: annual performance bonus of 3 to 7 percent, common in defense contract environments
• Equity: typically not offered at this level in aerospace MRO or defense manufacturing
• Health Benefits: medical, dental, and vision coverage; employer contribution varies by program
• PTO: 10 to 15 days annually, plus federal holidays, with shift-differential eligibility common
• Common Perks: tool allowance, safety gear provision, tuition assistance for aviation certifications

Figures are estimates based on general US market benchmarks and may be outdated. Adjust based on location, company size, and seniority level.

Employment in this position is contingent on successful completion of a background check and, where applicable, a security clearance adjudication. All qualified applicants will be considered without regard to race, color, religion, sex, national origin, age, disability, veteran status, or any other characteristic protected under applicable federal, state, or local law. Candidates requiring a reasonable accommodation to participate in the hiring process should notify the recruiting team. Applicants must be authorized to work in the United States.

The Aircraft Inspector 1 delivers detailed visual and dimensional inspection of composite parts and assemblies across the full manufacturing process, ensuring quality and design verification against prescribed specifications. Working alongside production personnel at all organizational levels, this role shapes product acceptance decisions that directly uphold manufacturing quality standards.

Key Responsibilities

• Inspects composite parts and assemblies throughout the manufacturing process for quality and design verification.
• Uses predetermined methods, operations, setups, and prescribed specifications to inspect in-process and completed products.
• Works from inspection instructions and checklists to determine compliance with stated requirements.
• Makes accept-and-reject decisions on inspected products.
• Performs close-tolerance dimensional checks and general surveillance of work in progress.
• Inspects mechanical final assembly installations of detail parts into assemblies.
• Inspects systems, including hydraulic and electrical installations.
• Uses measuring devices, including microscopes, micrometers, calipers, and scales, as defined in work instructions.

Required Qualifications

• High School Diploma or equivalent GED required.
• Proficiency in standard measuring and inspection tools and equipment, with the ability to read and understand blueprints, technical specifications, and operating procedures.
• Proficiency in Microsoft applications.
• Ability to work independently and in a team setting.
• Strong interpersonal communication skills with the ability to work with others at all levels of the organisation.
• Strong attention to detail and accuracy.
• Ability to multitask and prioritise.
• Ability to sit and/or stand for long periods of time.
• Ability to certify for half- and full-face respirator use.
• Ability to work around composites, epoxies, and sealants for long periods of time.
• Ability to work flexible and changing shift schedules.

Embedded within the modification and maintenance quality function, the Aircraft Inspector V leads cross-functional teams to resolve quality problems while overseeing inspections of completed aircraft modification and maintenance actions against written specifications and blueprints. Working closely with DCMA, subcontractors, and modification and maintenance personnel, this role builds a sustainable quality culture that drives reliability across the total modification and maintenance effort.

Core Functions

• Inspects completed aircraft modification and maintenance actions to written specifications and blueprints.
• Inspects ground handling operations of aircraft throughout the modification and maintenance process.
• Ensures procedures are followed and resolves quality-related issues.
• Maintains and improves the quality, uniformity, and reliability of the total modification and maintenance effort.
• Performs inspections and tests and ensures others perform appropriate inspections and tests.
• Ensures products and processes are within specification.
• Oversees and ensures the quality of work performed by subcontractors.
• Presents product to and liaises with DCMA.
• Performs detailed kitting inspections.
• Leads and facilitates cross-functional teams to solve quality problems.
• Uses corrective actions to drive change and improve training, work habits, and procedures of modification and maintenance personnel.
• Establishes, tracks, analyses, and reports on key quality metrics.
• Maintains and improves the Quality Management System.
• Actively participates in establishing and promoting a quality culture.
• Conducts safety inspections and training of modification and ground handling operations.
• Conducts internal audits of manufacturing and modification processes.
• Supports the FOD Prevention Programme.

Qualifications & Experience

• 10 years of aircraft maintenance experience, including 5 years as an aircraft Quality Inspector, is required.
• Experience with modification and maintenance of aircraft, releasing of safe aircraft, assembly and testing of components, and applicable inspections.
• Proficiency in reading and interpreting specifications, including blueprints and drawing packages.
• Proficiency in using basic inspection tools, including calipers, micrometers, depth gauges, hole gauges, and radius gauges.
• Experience working with government customers and programmes, including DCMA.
• Strong leadership abilities and interpersonal skills, with the ability to mentor and coach team members.
• Strong problem-solving skills.

Reporting to the quality assurance organization, the Aircraft Inspector shapes final product integrity by conducting comprehensive visual, physical, and systems inspections of heavy fixed-wing aircraft, including fuselage, wings, landing gears, engines, and hydraulic and electrical installations. Partnering with DCMA and cross-functional maintenance teams, this role enables mission-ready aircraft delivery by ensuring all modification and maintenance work meets AS9100 and DoD standards.

Primary Duties

• Inspects mechanical final assembly installations of the aircraft, including fuselage, wings, flaps, landing gears, engines, and tail assemblies.
• Inspects fuel tank internal areas and assemblies for final closure.
• Inspects systems, including hydraulic, pneumatic, oil, heat, and brake systems.
• Visually and physically inspects electrical installations.
• Rechecks work after adjustment or repair.
• Monitors and verifies quality in accordance with statistical processes or other control procedures.
• Maintains necessary inspection logs and writes inspection reports.

Skills & Qualifications

• High School Diploma with a minimum of 4 years of heavy aircraft maintenance and QA inspection experience on fixed-wing, multi-engine aircraft.
• Bachelor's Degree from an accredited university.
• USAF Level 5, 7, or 9 experience.
• An active DoD Secret Clearance is required.
• Experience and knowledge of AS9100 standard requirements and DCMA INST 8210.1 requirements.
• Familiarity with Root Cause Corrective Action tools and processes.
• Experience with Manufacturing Execution System tools.
• Intermediate or higher proficiency with MS Office Word, Excel, and PowerPoint.