APQP Engineer

Location: Gastonia, North Carolina Job Type: Full-time Industry: Manufacturing / Metal Fabrication Why Join IFAB Corp.? At IFAB Corp., we are a leading manufacturing company specializing in high-precision metal fabrication, assembly, and coating services. Our state-of-the-art facility features cutting-edge technology, including advanced lasers and coil stamp machinery. We take immense pride in our culture of quality, safety, operational excellence, and continuous innovation. We are seeking a detail-oriented and proactive APQP Engineer to lead new product launches, ensure robust manufacturing processes, and deliver defect-free parts to our OEM customers from day one. Role Overview As our APQP Engineer, you will own the Advanced Product Quality Planning process from quote award through production launch. You will work closely with Engineering, Tooling, Production, Quality, and Customers to plan, validate, and launch new and changed parts across stamping, laser cutting, tube bending, forming, welding, assembly, and finishing (e-coat and powder coat). You will directly impact launch success, customer satisfaction, and long-term product quality.

Key Responsibilities

• APQP Program Management: Lead the five phases of APQP for new and changed parts, managing timelines, deliverables, and gate reviews to ensure on-time launches.
• PPAP Preparation & Submission: Prepare, compile, and submit complete PPAP packages (Levels 1–5) per AIAG and customer-specific requirements, and secure customer approval.
• Core Quality Tools: Develop and maintain Process Flow Diagrams, PFMEAs, Control Plans, and work instructions; lead cross-functional teams in risk assessment and mitigation.
• Feasibility & Design Reviews: Review customer drawings, GD&T, and specifications; lead team feasibility analyses and identify manufacturability risks early.
• Measurement & Process Validation: Plan and execute MSA (Gage R&R), dimensional layouts, capability studies (Cpk/Ppk), and run-at-rate trials to validate process readiness.
• Customer & Supplier Interface: Act as the main quality contact for OEM customers during launch; coordinate with suppliers on sub-component and coating PPAPs.
• Engineering Change Management: Manage engineering changes, update quality documentation, and ensure smooth transitions into production.
• Continuous Improvement: Support root cause analysis (8D, 5 Why, Ishikawa) and corrective actions, applying lessons learned to future launches.
• Safety & Sustainability: Active commitment to Environmental, Health, and Safety (EHS) standards, maintaining a safe, compliant, and sustainable production environment.

Qualifications & Requirements

• Experience: 3+ years of APQP/PPAP experience in automotive, heavy truck (Class 6–8), agricultural equipment, or a related metal fabrication environment.
• Technical Proficiency: Strong knowledge of AIAG core tools (APQP, PPAP, FMEA, MSA, SPC) and IATF 16949 / ISO 9001 requirements; ability to read and interpret blueprints and GD&T.
• Process Knowledge: Familiarity with stamping, laser cutting, welding (MIG/TIG, spot, robotic), and coating processes is highly preferred.
• Core Skills: Project management, cross-functional leadership, problem-solving, and clear communication with customers and internal teams.
• Software: Proficiency with Microsoft Office; experience with ERP systems, customer portals, and statistical software (e.g., Minitab) is a plus.
• Education: Bachelor’s Degree in Mechanical, Industrial, Manufacturing, or Quality Engineering, or a related field.
• Certifications (Preferred): ASQ CQE, AIAG Core Tools, or Lean Six Sigma certification is a strong plus.
• Language: Bilingual English/Spanish is a plus.

What We Offer

• Competitive compensation package.
• Comprehensive health, dental, and vision insurance.
• 401(k) matching program.
• Paid Time Off (PTO) and paid holidays.
• Career growth opportunities within a fast-growing, tech-driven manufacturing leader.