Quality Engineer - Manufactuing

SUMMARY
This is a technical position responsible for supporting product quality assurance functions. Key job functions include new product quality system & tool development, achievement of customer PPAP approval, providing world class support of product quality at external customers, providing support to internal production operations, administration of internal quality systems, and performing root cause problem solving activities in support of quality defect elimination.

RESPONSIBILITIES AND DUTIES
New Product Development

• Performs Quality function assignments during product Design Input and Design Output process to ensure all aspects of product quality and quality tools are considered and optimized.
• Develops, uses, and maintains APQP quality documents including but not limited to PFMEA, Process Flow/Control Plan, Quality Inspection Standards, First/Last Piece Instructions, Receiving Inspection Instructions, Dock Audit Instructions, Safe Launch Instructions, etc.
• Ensures quality plans are in compliance to all related statutory and regulatory requirements.
• Reviews, interprets, and communicates technical drawings and other technical information needed to assure the compliance of products or processes. (GD&T, DV / PV testing requirements, SC, CCs, KPI, etc.)
• Utilizes Measurement Systems Analysis techniques to qualify gages, fixtures, and other metrology equipment as needed.
• Utilizes statistical analysis to determine process normality and capability through the use of statistical analysis. (P values, PPK, CPK, etc...)
• Supports Corporate Supplier Quality Engineering with development of supplier product, critical review/critique of drawings/tolerances, review/approve quality control plans, attending supplier run at rates as needed, and critical reviews and approval of supplier PPAPs.
• Manages Appearance Approval Report (AAR) process including directing colorant, paint, film, and purchased component suppliers, developing internal color tolerance values, attending customer color harmony events, and proactively engaging customer color harmony through life of production.
• Ensures compliance with all unique customer specific quality requirements throughout the product development cycle.
• Assembles all PPAP information at pre-launch as well as for subsequent post launch changes and submits or presents to customer.
• Accesses, updates, and maintains all customer web based applications utilized during product development.
• Performs and oversees safe launch containment inspections and determines corrective actions for safe launch findings.
• Supports all launch preparation activities including training of associates, internal development trials, customer run at rates, on-site customer builds, Launch Readiness Reviews, and Launch Effectiveness Reviews.
• Provides proactive / prior to launch training and support to on-site quality liaisons at customer facilities for all new products.

Customer Product Quality Support

• Develops and maintains positive working relationships with external customers.
• Engages immediately in reaction to customer quality concerns, and escalates to Quality Manager and Manufacturing management.
• Travels to customer locations as required to support containment, investigation, and presentation of corrective actions (or disputes) for customer quality concerns.
• Breakdowns and reviews customer warranty data to apply corrective actions and proper responses up and including on-site review and investigation at the customer as needed.
• Travels routinely to customer for proactive visits and customer build events.

Internal Product & Quality Systems Support.

• Provides support for internal plant operations enabling the production of high quality, high value products for our customers.
• Provides functional and technical knowledge and research in support of manufacturing operations in resolving quality concerns and questions.
• Develops, maintains and performs internal Layered Process Audits and analyzes findings to take appropriate corrective actions.
• Participates in other auditing activities including but not limited to customer audits, internal quality audits, supplier quality audits, and internal/external IATF / ISO audits.
• Supports and participates in continuous improvement activities that create improvements to standardized work methods and operational efficiency.
• Uses industry standard metrology equipment to qualify and calibrate as needed products, processes, or fixtures / tools.
• Provides guidance to quality inspectors / technicians in performing their responsibilities.
• Provides support when required during off hours relating to any topic related to the above mentioned duties.

Problem Solving

• Leads, performs and supports Practical Problem Solving (PPS) activities to fully define the problem, determine root cause, and develop root cause based corrective actions to resolve customer, internal and supplier quality concerns.
• Documents corrective actions on PPS A3 format, and when required on specific customer problem solving / corrective action formats.
• Shares corrective actions with other affected functions, including corporate teams, sister plants, and suppliers.

EDUCATION AND EXPERIENCE

• Bachelor's Degree in an Engineering field or related science discipline is preferred
• 3-5 years of experience in automotive quality function is required alternate to degree
• ASQC CQE certification is a plus
• Experience as Internal Auditor for IATF 16949 / ISO 9001 is a plus
• Agreement to complete all post-hire required training is required

SKILLS AND ABILITIES:

• Strong computer litteracy, including Microsoft Excel, Word, Power Point and customer websites
• Knowledge of AIAG based quality core tools including APQP, PPAP, MSA, GD&T, & FMEA
• Problem Solving Methodologies (Toyota Practical Problem Solving, 8D, etc.)
• Knowledge and understanding of IATF 16949 / ISO 9001 Standards
• Knowledge of Metrology tools and methods
• Knowledge of SPC & Statistical Analysis and related software skills (Minitab or similar)
• Interpersonal skills necessary to effectively interact with all levels of Summit Polymers and customer organizations, including performing effective negotiations, leading effective training, presenting problem solving results, etc.
• Excellent written and oral communication skills