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Senior Quality Engineer

 

Job Description

Job Title: Sr. Quality Engineer Location: Geneva, IL

Department: Quality Reports To: Quality Manager

Primary Job Function

Sr. Quality Engineer is responsible for the day to day support of the Plant 1 Manufacturing Operations of Burgess Norton. They manage a team of hourly staff and / or Associates which carry out inspections and process monitoring. The Sr. Quality Engineer will serve as the backup / delegate for the Quality Manager.

Sr. Quality Engineer develops and executes process that will support the quality objectives, financial metrics, KPI’s and support Engineering, Production and Material/Scheduling. The work of quality Engineering is predominantly the development and establishment of quality system; analysis of manufacturing process quality, the application of the quality plan and the improvement of controlling process quality. The Sr. QE will also oversee the control of measurement equipment; inspection and testing.

In support of BN’s quality initiatives, the Sr. Quality Engineer will be responsible for supporting global initiatives in all international locations as needed. The activities will include implementation of quality system, validation, testing, SPC, internal auditing and machine capabilities.

Specific Job Responsibilities

Leadership

  • Lead, manage, and develop hourly staff members
  • Lead Problem Solving Teams
  • Coordination of product sorting and certification processes
  • Coordination of Hourly and / or Associate Workforce (scheduling and work instructions)
  • Manage Visual Inspection Requests, and provide structure and ensure value in the process
  • Management of NCMR Hold Areas.

Internal Factory Quality

  • Review and Disposition of NCMR Material
  • Maintain applicable core quality documents (PFC, PFMEA, QCP, Work Instructions)
  • Design and implement methods for process control, process improvement, testing and inspection
  • Monitor and report the status of quality issues, trends and losses
  • Participate in internal and external quality audits
  • Develop and deliver training material on quality standards, activities and SPC
  • Lead Continuous Improvement Team(s) and other activities to determine actions to improve the quality system and reduce the cost of quality
  • Assist with PPAP’s for customers of our products
  • Monitor and lead actions to improve key indicators as FTQ, Scrap and Rework
  • Oversee incoming audit process and dock audit
  • Monitor and improve the LPA process
  • Support activities for applicable CQI standard conformance
  • Assist in the Internal and External Audit Processes
  • Support Sales and Engineering for Prototype Delivery and PPAP Documentation
  • Perform other duties and projects as assigned.

Global Best Practices

  • Support other BN plants including training, Internal Auditing or support as necessary to improve global standards and best practices
  • Travel Requirement up to 15% with some extended international trips
  • Perform other duties and projects as assigned.

Customer Satisfaction

  • Assist with Customer Corrective Action Reports, and data collection (primarily 8D and 5 Why)
  • Visit customers to address complaints, host audits, perform process/product validations, and attend on-site training and service
  • Visit supplier to perform internal audits, develop criteria for quality acceptance, develop material sources, check on methods and equipment to make sure they meet and maintain quality standards and approve suppliers
  • Perform other duties and projects as assigned.

Supplier Development

  • Manage Supplier Corrective Actions
  • Evaluate supplier performance, coordinate approval of initial samples provided by suppliers and establish and monitor systems for recording and reporting supplier conformance to quality
  • Visit suppliers to perform internal audits, address customer complaints, develop criteria for quality acceptance, develop material sources, observe methods and equipment to make sure they meet and maintain quality standards and provide suppliers approval to Purchasing
  • Perform other duties and projects as assigned.

 

Job Qualification Profile

  • Bachelor’s degree in an engineering or related discipline
  • Demonstrated success in establishing a Zero Defect culture
  • Strong Team orientation, honest, ethical, fact-based, acts with a sense of urgency, executes, and achieves desired results
  • Strong communication skills (oral and written) with the ability to communicate to all levels within the organization as well as external to the organization
  • Knowledge of Geometric Dimensioning and Tolerancing (GD&T)
  • Experience with machining process metrology
  • Strong statistical background including the use of SPC within the manufacturing process to measure and sustain capability
  • Three years of experience with ISO and TS 16949 Quality Systems as an Internal Auditor
  • Understanding of APQP, PPAP, PFMEA, and new product launches
  • Proficient with Microsoft Office, especially Excel Pivot Tables
  • Demonstrated ability as primary point of contact for Customer Quality issues and Corrective Action/Preventative Action
  • Experience performing and managing the visual inspection of product
  • Knowledge of Quality System Basics, Fast Response, Early Part Containment, Corrective/Preventive Action
  • Experience in a Quality Support Role to Automotive OEM manufacturing plants (Worked directly with Automotive OEM manufacturing facilities)
  • Five years in Quality Control, three years of experience supervising others.

Preferred Experience:

  • ASQ Certified Quality Engineer (CQE), or Six Sigma Black Belt or Green Belt strongly preferred
  • Experience with the Heat Treatment of Steel
  • Operation / Auditing of Surface Coating Systems
  • Spanish Speaking / Writing Skills
  • SAP Quality Module Experience
  • Experience operating or supporting centerless grinders.