Description Responsibility to function as a Quality Engineer who owns quality problems from detection through permanent resolution, following all IATF 16949 instructions. Responsible for maintaining a strong, open, and honest relationship with our customers. Manage customer concerns or complaints, and customer and internal timelines. Support the Engineering Manager and Program Managers during the APQP & PDP process. Lead root cause analysis with production, maintenance and engineering using structured problem solving (A3 / 8D): verify root cause with evidence, address both why the problem occurred and why it escaped and implement permanent corrective actions that prevent recurrence. Maintain basic understanding of our manufacturing process, enough to connect a defect to its process, tooling or fixture cause. Follow the procedures and systems to ensure that the product or service that Exo-s provides is to design intent and meet both external and internal requirements, including legal compliance and customer expectations. Coordinate the activities required to meet quality standards, ensuring that processes are delivering their intended output. Monitor and advise on the performance of the product. Work with the Production and Technical staff to ensure that the Quality system is functioning properly. Where appropriate, advise on changes and their implementation and coach others in the tools and techniques of problem solving and quality. Follow the AIAG and Customer standards when PPAP is required.
PRINCIPLE DUTIES, RESPONSIBILITIES AND ESSENTIAL ELEMENTS OF THE JOB
- Implement containment for internal or external non-conforming material, then drive the issue to verified root cause and permanent corrective action.
- Implement and monitor containment/Safe Launch at the start of new programs or engineering changes.
- Communicate with production staff, Program Managers, and management staff of all customer concerns.
- Manage supplier SCARs and hold suppliers to verify root cause and effective corrective action.
- Own customer concerns from containment through closure using A3 / 8D problem solving, with root cause verified by evidence.
- Investigate problems at the line, implement permanent corrective actions (error-proofing, process or tooling changes, control plan updates), and verify effectiveness with data 30 to 60 days after implementation.
- Apply each corrective action across similar lines, molds, fixtures and sites where the same failure could occur (read across).
- Take ownership of assigned problems through closure, and present problem-solving work.
- Own all quality tasks from our Product Development Process when assigned as the program quality Engineer.
- Manage and update Lessons Learned, PFMEA’s, Control Plans, Process Flow, and Work Instructions so that every corrective action and lesson learned is reflected in them.
- Perform and Analyze capability studies at launch.
- Set standards and establish clearly defined quality methods of inspection for staff to apply.
- Identify relevant quality-related training needs, assist in the training process, and coach operators and technicians in problem-solving tools.
- Ensure all containments, re-work and deviations are properly understood, carried out and evaluated and that product modifications are investigated if necessary.
- Lead continuous improvement on assigned lines, using quality data to find and eliminate recurring defects.
- Liaison with customers and plant reps to ensure execution of corrective action and compliance with customers’ specifications.
- Establish standards for customers’ requirements.
- Monitor performance by gathering and analyzing data, producing statistical reports, and acting on trends before they reach the customer.
- Assist in conducting internal quality audits.
- Assist with final approval in all quality department functions.
- Participate in APQP planning through production launch.
- Perform and submit Supplier
- Other duties as assigned
KEY MEASURABLES
- On time corrective actions
- Recurrence rate of closed issues (repeat defects)
- Percentage of corrective actions verified effective
- Quality of A3 / 8D problem solving, scored against the department standard
AUTHORITY
- Help establish quality standards for processes and products.
- Disposition of material on hold
- Stop shipment of product if quality is suspect
- Stop production to correct quality problems
- Placement of product on hold
- Implement containment
- Issue and approve purchase orders or work orders for sub-contractor/vendors for sorting, calibrations, repairs and purchases of measurement devices.
Requirements
- 5 years experience in Quality Assurance.
- Team player / good attitude
- Working knowledge of quality management tools such as SPC, PFMEA, CP, MSA, and structured root cause analysis (8D, A3, 5 Why, fishbone, is / is-not)
- Quality experience in a manufacturing environment, preferably blow molding with a strong understanding of geometric dimensions and tolerance
- Demonstrated record of leading root cause investigations to permanent, verified corrective action (examples expected at interview)
- Curiosity and initiative: digs past the immediate fix to understand why a problem happened
- Strong organization and follow-through on commitments and deadlines
- Ability to travel to customer locations
- Strong written, verbal and interpersonal communication skills
- PC Skills to include MS word, excel, power point and ability to create spreadsheets.
- Ability to work independently as well as part of a team.
Physical Requirement
- Must be able to physically perform the basic life operation functions of climbing, balancing, stooping, kneeling, crouching, crawling, reaching, standing, walking, pushing, pulling, lifting, talking, hearing, and repetitive motion.
- Must possess the visual alertness to operate equipment and motor vehicles, perform trades, tasks, inspect the work of others, and review work for accuracy, neatness, and thoroughness.
- Reasonable accommodations may be made to enable individuals with disabilities.
Benefits
- Competitive Pay
- Generous Paid Time Off
- 10 Paid Holidays
- Medical, Dental & Vision Benefits, Day One
- Employer-Paid Life Insurance
- Paid Paternal Leave
- 401k with Employer Match
- Tuition Reimbursement
- Employee Referral Bonus
- Supportive Team Culture!
- Our Values Guide how we work together: Teamwork, Trustworthy, Entrepreneur, Balance, and Fun Factor!
- Your Efforts Matter Here!
