The Quality Assurance Manager is responsible for leading, developing, and managing the plant's quality management system (QMS), quality engineering, and quality inspection functions. This role ensures that all products - spanning residential and industrial electrical markets - consistently meet or exceed customer expectations, internal standards, and all applicable domestic and international regulatory requirements. The Quality Assurance Manager drives a culture of data-driven decision making, continuous improvement, and operational excellence. This position directly leads a team of Quality Engineers and Quality Technicians and reports to the Plant Manager.
Responsibilities:Quality Management System (QMS) Leadership
- Own, maintain, and continuously improve the plant's QMS in compliance with ISO 9001:2015 and lead the transition to ISO 9001:2026 upon publication, including gap analysis, updated documentation, internal audits, and staff training aligned with the new standard's emphasis on quality culture, ethical behavior, and enhanced risk-based thinking.
- Plan, schedule, and lead internal audits; manage external/third-party certification audits and customer audits. Ensure audit findings are resolved with robust corrective and preventive actions (CAPA).
- Develop and maintain quality policies, procedures, work instructions, and other controlled documentation in accordance with QMS requirements.
Regulatory & Standards Compliance (Global)
- Serve as the plant's subject matter expert on UL standards, qualification testing, and the UL approval/listing process for electrical products, including managing UL file reviews, follow-up inspections, and new product submissions.
- Ensure product compliance with global regulatory and market-specific requirements including, but not limited to:
- RoHS (Restriction of Hazardous Substances)
- California Proposition 65
- CE Marking (EU Low Voltage Directive, EMC Directive, etc.)
- ASME standards
- DIN standards
- REACH, WEEE, and other EU environmental directives
- CSA, ETL/Intertek, and other NRTL certifications
- Country-specific regulatory bodies (e.g., CCC for China, PSE for Japan, SAA for Australia, SASO for Saudi Arabia, etc.)
- Monitor evolving regulatory landscapes across global markets and proactively communicate impacts to engineering, product management, and operations teams.
Data-Driven Quality & Statistical Methods
- Champion a data-driven decision-making culture across the quality organization and plant floor. All quality decisions, dispositions, and improvement initiatives must be supported by quantitative analysis.
- Apply and coach the team in the use of statistical quality methods and tools including:
- Statistical Process Control (SPC) - control charts, process capability indices (Cp, Cpk, Pp, Ppk)
- Measurement System Analysis (MSA) - Gage R&R studies
- Design of Experiments (DOE)
- Hypothesis testing, regression analysis, ANOVA
- Reliability analysis (Weibull, MTBF, life testing)
- Acceptance sampling plans (ANSI/ASQ Z1.4, Z1.9, LTPD, AQL)
- Pareto analysis, cause-and-effect diagrams, FMEA (Process & Design)
- Develop and maintain quality dashboards and KPIs (PPM, COPQ, first-pass yield, scrap rate, customer complaint rates, audit scores, etc.) and present actionable insights to plant leadership.
Six Sigma & Continuous Improvement
- Apply Six Sigma methodology (DMAIC/DMADV) to lead and facilitate cross-functional improvement projects that reduce variation, eliminate defects, and improve process capability.
- Familiarity with Lean Manufacturing principles (5S, Kaizen, value stream mapping, waste reduction) and their integration with quality systems.
- Drive root cause analysis using structured problem-solving methods (8D, 5-Why, Ishikawa, fault tree analysis).
- Lead or sponsor continuous improvement initiatives aligned with plant goals and customer requirements.
Inspection, Metrology & Quality Equipment
- Oversee the selection, calibration, maintenance, and effective use of both legacy and modern quality and inspection equipment including:
- Coordinate Measuring Machines (CMMs) - contact and non-contact
- Vision inspection systems (2D/3D automated optical inspection, machine vision cameras)
- Optical comparators and profile projectors
- Hardness testers, surface roughness testers
- Pin gages, thread gages, ring gages, go/no-go fixtures
- Calipers, micrometers, height gages, dial indicators
- Electrical test equipment (hi-pot testers, insulation resistance testers, continuity testers)
- Force/torque measurement devices
- Manage the calibration program ensuring all measurement and test equipment is traceable to NIST or equivalent national standards and within calibration intervals.
- Evaluate and implement emerging inspection technologies (e.g., inline automated vision, AI-assisted defect detection) where ROI and quality improvements justify adoption.
Team Leadership & Development
- Directly manage, mentor, and develop a team of Quality Engineers and Quality Technicians, including performance management, goal setting, training plans, and succession planning.
- Foster a team culture of accountability, technical curiosity, and continuous professional development.
- Ensure adequate staffing and skill coverage across shifts and product lines.
- Conduct regular team meetings, performance reviews, and cross-training initiatives.
Supplier Quality Management
- Establish and maintain incoming inspection criteria and supplier quality requirements.
- Lead supplier audits, corrective action requests (SCARs), and supplier development activities.
- Collaborate with procurement and engineering to qualify new suppliers and manage approved supplier lists.
- Monitor supplier quality performance metrics and drive improvement where needed.
Customer Quality Interface
- Serve as the primary quality contact for customer complaints, returns (RMA), and quality escalations.
- Lead customer complaint investigations, ensure timely and thorough root cause analysis, and implement effective corrective actions.
- Support customer audits and quality-related inquiries.
- Participate in new product development and design reviews (APQP, PPAP concepts where applicable) to ensure quality is designed in from the start.
Qualifications:- Bachelor's degree in Quality Assurance, Engineering, Manufacturing, Business Administration, or related field.
- Preferred certifications include:
- Certified Quality Manager (CQM) - ASQ (highly preferred)
- Certified Quality Engineer (CQE) - ASQ
- Six Sigma certification (Green Belt required; Black Belt preferred)
- ISO 9001 Lead Auditor certification or equivalent quality systems certification
- Lean Manufacturing certification (preferred, especially in industrial environments)
- 5-10+ years of progressive experience in quality assurance, quality control, or manufacturing environments.
- 2-5+ years of leadership or supervisory experience managing QA teams.
- Demonstrated experience implementing and maintaining Quality Management Systems (QMS).
- Experience with regulatory compliance (e.g., ISO standards, FDA, OSHA, or industry-specific requirements.)
- Proven track record of leading teams, process improvement initiatives, and driving continuous improvement.
The expected salary for this position is between $86,985.00 and $116,995.00 per year. This range represents a good faith estimate for the position and actual compensation will be based on numerous factors including knowledge, location, skills, training and experience.
IDEAL employees enjoy a wide range of valuable benefits including:
- Medical, Dental & Vision Insurance
- Education Reimbursement
- Wellness Programs
- 401k with Company Match
- Cash Balance Pension Plan
IDEAL values rest, personal time and community involvement facilitating these through several paid time off programs including:
- Vacation
- Personal Days
- Volunteer Time
- Holidays
- Parental Leave
