The Quality Engineer is responsible for supporting the plant's Quality Management System (QMS), executing audit activities, driving continuous improvement initiatives, and supporting manufacturing quality objectives. This position works closely with operations, engineering, suppliers, and customers to improve product quality, ensure compliance with quality standards, and enhance process performance.
The PositionThe Quality Engineer is responsible for supporting the plant's Quality Management System (QMS), executing audit activities, driving continuous improvement initiatives, and supporting manufacturing quality objectives. This position works closely with operations, engineering, suppliers, and customers to improve product quality, ensure compliance with quality standards, and enhance process performance.
Salary Range: $110,000/year to $125,000/year
Key Responsibilities - Execute plant quality auditing activities and conduct internal quality system and process audits.
- Serve as Lead Auditor for plant quality system and process audits.
- Organize and coordinate plant calibration activities.
- Supervise and schedule the plant's hourly specialty (mechanical) testers.
- Participate in the disposition of internal nonconformances and external customer returns (RGAs).
- Assign, track, and maintain Corrective Action Requests (CARs) and verify implementation effectiveness.
- Support shipping certification activities for specialty products.
- Maintain PPAPs, Control Plans, Process Flow Diagrams, and PFMEAs.
- Lead and participate in disciplined problem-solving activities utilizing methodologies such as 8D, 5 Whys, and Root Cause Analysis.
- Lead and participate in process improvement and continuous improvement initiatives.
- Participate in the Management of Change (MOC) process to evaluate and mitigate quality risks.
- Complete Measurement Systems Analysis (MSA) and Gage R&R studies.
- Implement and maintain data collection systems for critical quality metrics.
- Collect, analyze, and interpret quality and process data to identify trends and opportunities for improvement.
- Participate in the creation, review, and maintenance of Standard Operating Procedures (SOPs) and Standard Work Instructions (SWIs).
- Design and implement tools, equipment, inspection methods, and process controls to improve product quality and manufacturing performance.
- Support supplier quality initiatives and supplier qualification activities.
- Participate in internal and external audits and support timely resolution of audit findings.
- Perform other continuous improvement and quality-related assignments as directed.
Job RequirementsEducation & Experience - Bachelor's degree in Engineering or a related technical discipline preferred.
- Minimum five (5) years of quality engineering experience in a manufacturing environment.
- Certified Lead Auditor for the ISO 9001 Quality Management System required.
- Strong knowledge of Quality Management Systems, auditing principles, and regulatory compliance requirements.
- Experience with PPAP, Control Plans, Process Flow Diagrams, PFMEA, MSA, SPC, and Root Cause Analysis methodologies.
- Knowledge and experience in Six Sigma, Lean Manufacturing, Total Quality Management (TQM), Kaizen, Design of Experiments (DOE), FMEA, and other continuous improvement methodologies preferred.
- Strong background in supplier management and supplier qualification processes.
- Superior organizational, analytical, problem-solving, multitasking, written, and verbal communication skills.
- Effective negotiation, conflict resolution, presentation, and facilitation skills.
- Ability to work effectively with employees at all levels and external business partners while maintaining a positive, customer-focused approach.
- Strong leadership and influence capabilities.
- Ability to perform effectively as both a team leader and team member.
- Must be able to communicate effectively in English, both verbally and in writing, to follow safety procedures, understand work instructions, complete documentation, and communicate with coworkers and supervisors.
- Proficiency with Microsoft Excel, Word, PowerPoint, Access, Project, and quality management software applications.
Preferred Qualifications - Experience with Lean Manufacturing, Six Sigma, Continuous Improvement, Kaizen, and Total Productive Maintenance (TPM).
- Demonstrated experience implementing Lean tools and methodologies including:
- Value Stream Mapping
- 5S
- Kanban/Pull Production Systems
- Visual Management
- Standardized Work
- Root Cause Analysis
- Continuous Flow Manufacturing
- Knowledge of ISO 9001 Quality Management Systems.
- Experience in a union manufacturing environment.
Physical Requirements - Must be able to use a variety of hand tools such as wrenches, screwdrivers, hammers, etc.
- Must be able to work in a dusty environment around metals
- Sight - hand and eye coordination, depth perception needed to operate, adjust, and quantify chemicals and equipment, vision sufficient to inspect work areas and building for issues and operate computers
- Hearing - must be able to hear others and warning sounds of forklift and other heavy machinery
- Speech - must be able to communicate effectively with others while working
- Smell - must be able to smell various chemicals and gasses
- Must be able to sit, stand, and walk for long periods - frequent to constant
- Must be able to squat, stoop, twist, climb, crawl, reach, grasp, and fine manipulation, and bend occasional to frequent
- Must be able to be able to lift/carry 50+ lbs - occasional
Success Measures - Successful execution of internal and external audit requirements.
- Reduction in quality defects, scrap, and customer complaints.
- Timely closure and effectiveness of corrective actions.
- Improvement in process capability and operational performance.
- Effective maintenance of quality documentation and records.
- Successful implementation of continuous improvement initiatives and quality improvement projects.
