Job DescriptionSummary:The Quality Manager is responsible for overseeing all quality assurance and control activities at the injection molding manufacturing site. This includes ensuring that all molded components and assemblies meet customer requirements, internal quality standards, and applicable industry and regulatory specifications. The Quality Manager leads the site's Quality Management System (QMS), manages the quality team, and drives continuous improvement initiatives focused on reducing defects, improving process stability, and achieving operational excellence.
Key Responsibilities:Quality Management System (QMS):- Develop, implement, and maintain the site's QMS in compliance with BRC Packaging Issue 6.
- Maintain documentation and ensure proper control of quality procedures, inspection plans, and work instructions.
- Coordinate internal audits, customer audits, and third-party certifications; ensure timely closure of corrective actions.
Injection Molding Process Quality:- Oversee quality control of all injection molding operations, from raw material receipt to final product shipment.
- Establish and maintain process capability studies (Cp, Cpk) and dimensional verification using tools such as CMMs and vision systems.
- Monitor process parameters and collaborate with process engineers to ensure consistent mold performance and product conformity.
- Investigate nonconformances related to molding defects such as short shots, flash, sink marks, burn marks, and dimensional deviations.
- Implement robust corrective and preventive actions (CAPA) using root cause analysis techniques (e.g., 5 Whys, Fishbone diagrams, DMAIC).
Supplier and Material Quality:- Oversee incoming inspection of resin materials, colorants, and components for conformance to specifications.
- Work with suppliers to resolve material-related quality issues and implement supplier corrective actions.
- Maintain supplier scorecards and ensure consistent raw material quality to support stable molding processes.
Customer Quality and Compliance:- Serve as the primary quality contact for customer complaints, audits, and product validations (PPAP, FAI, FAIR).
- Ensure compliance with customer-specific requirements, including documentation, traceability, and dimensional reporting.
- Manage containment, root cause analysis, and corrective actions for customer returns or quality escapes.
Team Leadership and Training:- Lead, mentor, and develop quality inspectors, technicians, and engineers.
- Provide training to production and maintenance personnel on defect identification, quality standards, and inspection techniques.
- Promote a culture of accountability, precision, and continuous improvement throughout the plant.
Continuous Improvement and Data Analysis:- Analyze quality data (scrap, rework, first-pass yield, downtime) to identify trends and drive improvements.
- Lead kaizen and Six Sigma projects focused on defect reduction, mold performance, and process capability.
- Support implementation of Statistical Process Control (SPC) and mistake-proofing (poka-yoke) systems in production.
Qualifications:- Bachelor's degree in Engineering, Quality Management, Plastics Engineering, or a related technical field.
- 5-10 years of experience in quality management within an injection molding or plastics manufacturing environment.
- Strong understanding of injection molding processes, tooling, resin behavior, and process validation.
- Familiarity with quality tools: FMEA, PPAP, MSA, SPC, control plans, and root cause analysis methods.
- Experience with ISO 9001, Food Grade standard BRC issue 6, or similar standards.
- Proficiency with quality measurement systems (e.g., gauge calibration).
- Excellent communication, leadership, and problem-solving skills.
- ASQ CQE/CQM or Six Sigma certification preferred.
Key Competencies:- Deep understanding of injection molding quality parameters
- Strong analytical and troubleshooting abilities
- Effective cross-functional leadership
- Attention to detail and documentation accuracy
- Commitment to customer satisfaction and continuous improvement
