Plant Quality Engineer

RESPONSIBILITIES:

• Lead and approve APQP activities throughout development to post launch (VPDS G3 to G6) phase to ensure the quality of the event.
• Participate and co-ordinate with PD and manufacturing engineering during BOM quotes for new programs.
• Work with program team and interface with customer to ensure customer specific requirements (CSR) are followed through KPI’s.
• Review and understand customer scorecard and access customer portal to understand customer quality deliverables such as PPM and warranty targets, problem resolution expectations.
• Drive Team to review CSR and review in detail Quality items like Warranty, PPM, QR, MSA requirements, Dimensional, and provide feedback to CBU for feasibility. 
• Participate in technical design reviews and work with the program core team on developing risk assessment tools such as DFMEA, SCIF, PFMEA and Control plan.
• Ensure quality requirements are reviewed during design and launch reviews. 
• Ensure Design for Manufacturing, Design for Quality methods and Lessons Learned are incorporated by the Program Core Team.
• Lead Quality Core Tool Workshops (QCTW) and follow-up closure of opportunities defined in workshop.
• Participate and ensure integrity joint check workshop during Pilot phase of the program to ensure safe launch.
• Participate in internal and Customer Run at Rate to identify top process quality issues and address them through corrective actions.
• Prepare Quality inspection report for each prototype build and ensure product integrity.
• Track PPAP deliverables to customers during development and pilot phase (VPDS G3-G5).
• Work with tooling specialist to review and analyze dimensional data and quality of first tool tryout molded parts.
• Support all gauges’ development during Gate 1 to Gate 3. Ensure right gauges available in quote.  Purchasing, track and prove-out gauges (PD to define VSA, locating strategy, supplier, and gauge lay-outs), and responsible for gauges from gate 4-5.
  • PO, gauge timeline, tracking and coordinating with supplier
• Support Dimensional convergence engineer while completion of dimensional capability, gauge certification and gauge R&R studies.
• Develop and monitor with the Product Engineer and dimensional convergence engineer the overall dimensional plan for the program GD&T, number of measurement points, datum scheme, number of lamps to be measured at various stages of the program etc.
• Catalyst and coach for AIAG Core Tools application by all required areas, make training plans, and escalate noncompliance.
• Review quality department procedures and update/ train as required into education system database.
• Organize all QRE Tools like Suit-case testers are part of quote, ordered and built by New Models with assy line (or ordered separately), kit of spare of parts, etc.
• Lead team to use VPRS for test failures during development, drive teams to know root-cause before making PCA’s, and drive teams to make Lesson Learned Cards where applicable.
• Review component drawings and understand the application requirements for each component. Understand all performance and engineering specifications applied to the parts.
• Analyze, troubleshoot and follow up on internal & customer quality issues until responsible department is defined.
• Responsible for incoming parts quality inspection until incoming quality engineer is onboard.
• Work with organizations or suppliers to implement strategic advanced technologies at manufacturing locations to reduce yearly customer reported quality concerns to meet quality targets.
• As required, lead and manage Quality Resident Eng (QRE), Metrology Technicians (MT), Shift Inspectors (SI), Incoming Quality (IQ) or any other assigned quality function and third-party companies internally and in customer assembly plants.
• As a AQE Cover SPC, MT, IQE, SI, CS, ESD, CQE up to launch phase (Gate5) and share adequate resources are available and trained in Gate 5 to assigned quality function.
• Where team required activities are non-compliance, escalate to Program manager and functional Manager until resolved.
• Work with Core Team to build prototype and pre-production samples overseeing manufacturing process to ensure well defined prototype/pre-production control plans are followed. 
• Work with design /industrialization groups and make CAD 3D investigations/analysis to make mechanical, thermal, electrical, or software changes to resolve prototype and pre-production build and test issues.

EDUCATION REQUIREMENT(S):

• Minimum Bachelor degree in related engineering discipline.

EXPERIENCE REQUIREMENT(S):

• Minimum 3 years’ experience in quality for automotive OEM or Tier 1 Supplier
• Possess a strong understanding of Core Tools (APQP, SPC, MSA, FMEA & PPAP), Control Plans/Process Flows
• Knowledge of Root Cause Analysis/Practical Problem Solving.
• Proficient in and learning Business Operating Systems.
• Knowledge of various processes (i.e. molding, coating, assembly, electronics, etc.)
• Knowledge of basic concepts of design output, metrology, and instrumentation.
• Ability to travel frequently to multiple locations on an as-needed basis. Travel requirements will depend on the location of project launch

ADDITIONAL INFORMATION:

• Ability to travel frequently to multiple locations on an as-needed basis. Travel requirements will depend on the location of project launch