Quality Engineer

POSITION SUMMARY: The Quality Engineer's primary responsibility is to serve as a liaison between the customer and SA Automotive team during PPAP and life of the program ensuring our products meet the highest quality standards and comply with relevant regulations and customer requirements.

Responsibilities/Duties

• Corrective Actions: Serve as a team champion for all customer quality issues in order to complete effective corrective actions on time using such tools as 8-d, 5-D, Fish bone & test theory diagrams, Shainin Red X, 3x5 Why, 5-Why, is-is not theory, etc. Respond to customer concerns on time every time.
• PPAP: Serve as team champion to coordinate and complete all internal/external PPAP requirements in accordance with the timing communicated to the customers for Program Launch and Engineering Changes.
• Customer Relations: Develop and maintain harmonious relationship with customers to assure quality requirements are met and on-going customer satisfaction. This includes visiting customer sites as required
• PPAP: Lead team to coordinate and complete internal/external PPAP in accordance with customer specific requirements and timing. This includes ProgramLaunch and Engineering Changes
• Core Tools: Create/maintain AIAG core tools workbooks for each program/part assigned. This includes leading the team to create/update PFD, PFMEA, Control Plan, Dimensional layout, SPC, Capability (CpK/PpK), Gage R&R, Gage instructions, Standardized work and inspection instructions
• Gage Design: Work with customer contacts and outside Gage Manufacturers to design/ procure simple to complicated gages per the GD&T and internal requirements.
• Check customer web sites daily for customer rejects (service, production, & warranty) and PPAP/APQP deliverables.
• Control Plan: Responsible for the full implementation and verification of all Control Plan prevent/detect controls, control methods, reaction plans, etc.
• Job Instructions: Responsible to ensure work instructions, gage instructions and inspection instructions are clearly written, accurate and carry out the intent of the control plan at program launch, engineering changes and as needed through the change management process.
• Quality Alerts/Temporary Instructions: Initiate and publish quality alerts/temporary work instructions for internal/external concerns and changes to the production job book as appropriate.
• Gage R&R: Perform and evaluate Gage Repeatability and Reproducibility studies. Review resulting data to determine acceptance and implement effective corrective actions for sub-standard results.
• Standards/Masters: Obtain all program applicable standards, test methods/procedures and masters.
• SPC: Perform Capability Studies and provide guidance and feedback to the team on improvement efforts based on review of statistical data. Implement effective methods for the team to gather, report and react to on-going SPC requirements.
• Dimensional: Initiate and coordinate Dimensional Layouts (CMM or manual checks) per the print requirements with outside laboratories. Review resulting data from the dimensional layouts and translate into AIAG Dimensional reports.
• Validation: Initiate and coordinate materials and performance testing per the print requirements with outside laboratories. Initiate and gain customer approval of Design Validation Plans. Review resulting data to the criteria and determine acceptance. Work with all appropriate team members for resolution of open issues. Complete Design Validation Plan Report (DVP&R) and gain customer approvals as needed. Complete AIAG Materials and Performance workbooks in preparation for PPAP.
• Complete all Customer Required APQP documentation and work directly with the customer quality contacts during launch to ensure all customer quality needs are met.
• Complete all Customer Specific Requirements related to PPAP.
• APQP: Complete all tasks assigned through APQP/Gate review process within prescribed timing
• Problem Solving: Lead team for all quality issues (internal / external) within customer or internal prescribed timing. Initiate and publish quality alerts/temporary work instructions for internal/external concerns and changes to the production job book as appropriate
• Containment: Set up 3rdparty and internal containment as required. Initiate data tracking methods and fast response to nonconforming conditions. Ensure all containment personnel are trained and verify training effectiveness
• Appearance: Coordinate appearance approvals with suppliers and customers as required
• Continuous Improvement: Provide guidance and feedback to the team on improvement efforts based on review of statistical data.
• Implement effective methods for the team to gather, report and react to on-going requirements.
• Comply with safety regulations and maintain clean and orderly work areas (5S)
• Follow all clean up and housekeeping procedures (5S) i.e. production floor, shipping & receiving office and warehouse as needed
• May be required to perform other functions at the direction of the Quality Manager
  
  

Required Education, Experience & Training

• BS/BA Engineering, Business, or related field with a minimum of 0-2 years’ experience in automotive quality or an associate degree with a minimum of 2 years’ experience in automotive quality
• Working knowledge of GD&T
• Working knowledge of how to read and evaluate validation & dimensional reports
• MS Office (Word, Excel, PowerPoint)and Mini Tab