Quality Engineer - Holland, United States - Adient

Description

Responsibilities:

• Responsible for ensuring that continuous improvement is made in all Production Quality Deliverables (e.g.: RTY, Craftsmanship, RPPM, CPPM, SPPM, and Warranty/JD Power).
• Prepare PPAP packages for product submissions and approval by appropriate Customer personnel. Obtain approval of submission packages from the Product Service Manager or Quality Manager prior to submission to the Customer.
• Ensure that Customer and supplier quality issues are resolved using the Adient problem-solving methods (Kepner-Tregoe, 8-D, etc.).
• Perform gage studies (Gage R&R, Bias, Linearity, and Stability) before a gage is approved for production use, or after a product change (when applicable).
• Develop and update control plans, inspection plans, and containment plans as required.
• Support the Manufacturing Engineer in updating the PFMEA as required.
• Utilize all Customer-specific systems (e.g.: Stellantis PRISM, GM PRR, Ford WERS, Honda NARS).
• Conduct capability studies, ensure that they are properly performed, documented for special characteristics, and meet internal requirements (or a written Customer deviation is obtained).
• Support the continuous improvement of the Operation Description Sheets (ODS).
• Identify and utilize the appropriate statistical tools. Mentor team members on proper statistical application and techniques.
• Assess and approve post S.O.P. Supplier PPAPs.
• Interface with assigned external customers as the single point contact for issue resolution.
• Responsible for coordinating the preparation and on-time delivery of supplier AQP deliverables.
• Responsible for the completion of any customer-specific advanced quality planning requirements.
• Promote good customer relations by consistently providing premier customer satisfaction with a professional and friendly appearance and demeanor, can-do attitude, and willingness to help at all times.
• Able to resolve customer issues with a high sense of urgency, through providing fast responses to the customer, customer interaction, facilitating participation and including coordination of sorting/rework at the customer site.
• Performs other duties as assigned by the Quality Manager
• Safety: Study, institute and maintain efficient and safe work practices, procedures, facilities; by coordinating with the Human Resources, Safety, Maintenance and Engineering Departments and keep them abreast of all safety and efficiency requirements to maintain an accident-free, high efficiency plant operation
• Occasional Travel to support customer sites (10-25%)
• Portions of the job may not be standardized or completely described in the job description and may require some independent action and thinking by the employee. The job description outlined above is not intended to be a detailed list of job functions or responsibilities. It outlines the essential functions of the job. An individual may be required to perform other duties from time to time. The company reserves the right to amend, change or delete the contents of this description.

Qualifications/Experience:

• Bachelor's degree in Engineering required (individual may still be pursuing); (or equivalent experience) Specific education and training in Quality disciplines is required, including (minimum): ISO/TS16949, Continuous Improvement, Total Quality Management, PPAP, FMEA, Control Plans, DOE, and SPC
• Ability to read and interpret documents such as safety rules, drawings/blueprints (including understanding of GD&T) and procedure manuals. Candidate has the ability to write routine reports and correspondence.
• Math Skills: Through knowledge of SPC techniques and applications, including DOE & MSA.
• Candidate has the ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form.
• Must be computer literate and familiar with appropriate software programs. Candidate has the ability to create visual aids for communication purposes.
• Strong time management skills and customer focus
• Advanced analytical problem-solving skills to determine root cause of issues.
• Prefer three (3) years experience in manufacturing processes.
• Manufacturing Experience is required, with experience in automotive seating mechanisms strongly preferred.
• Experience in Welding (GMAW and Laser) and Assembly processes.
• Minimum 5 years in Quality Technician and/or Quality Engineer role, preferably in high volume manufacturing environment; 3 years automotive Tier 1/2/3 supplier experience preferred.

Customer Relations

• Promote good customer relations by consistently providing premier customer satisfaction with a professional and friendly appearance and demeanor, can-do attitude, and willingness to help at all times.
• Provide fast response to customer problems, including coordination of sorting/rework at customer site.

Problem-Solving & Corrective Action

• Provide timely feedback to the company regarding customer concerns.
• Participate with and/or direct problem-solving teams to resolve build and customer quality problems, with emphasis on systematic problem prevention.
• Provide thorough root cause analysis and permanent corrective action using 8-discipline (8D), 5-whys (5W), Ishikawa (fishbone) analysis, is/is not, six-sigma, design of experiments (DOE), measurement systems analysis (MSA), and other structured problem-solving techniques.
• Analyze results of structural testing failures to determine root cause and corrective action.
• Work with component and tooling/equipment suppliers to improve products and resolve manufacturing problems; may involve travel to customer or supplier location.

Production Quality Support

• Train quality and production personnel in quality requirements relating to specific programs, including proper use of control charts; utilize MSA & DOE when required.
• Set up statistical process control (SPC) on the manufacturing floor utilizing proper control charts; monitor and react to out-of-control conditions.
• Prepare written material for training or information (Quality Alerts, 8D, etc.).
• Maintain all part-specific documentation as outlined by AIAG, including:
• Gauge instructions
• Operator/quality check sheets
• Receiving inspection check sheets
• Control plans
• Process failure mode effects analysis (PFMEA)
• Process change notices
• Continuously improve process and product quality.

New Product Introduction

• Support product introduction process in plant-related activities, including prototype fabrication and delivery.
• Prepare and submit PPAP documentation per AIAG guidelines and IATF & business operating system (BOS)/quality management systems (QMS) requirements.
• Transfer print information, such as critical/significant characteristics and traditional/geometric tolerances to control plans, PFMEAs, and gauge concepts.
• Develop gauge concepts and procure gauges for specific programs.
• Support tooling and equipment runoffs as required.

Business Management

• Understand and adhere to BOS/QMS guidelines, methodologies, and requirements.
• Participate in Simultaneous Development Teams.
• Participate in internal audits as required.
• Perform other assignments as required

Qualification Requirements:

• Thorough knowledge of 8D process with emphasis on root cause analysis & systematic problem prevention
• Ability to resolve customer issues with a high sense of urgency through customer interaction, facilitating team participation and effective root cause analysis.
• Ability to use Microsoft Office, engineering graphics, statistical (Minitab or equivalent), & database software.

Education and Experience:

• 4 Year Technical or Bachelor's Degree, preferably in Engineering or Engineering Technical field; ASQ certification is a plus.
• Minimum 5 years as a Quality Engineer role, preferably in a high volume manufacturing environment; 3 years automotive with Customer Experience.

Language Skills:

• Ability to read, write, comprehend, and speak in English language.
• Excellent written and verbal communication skills; including ability to present to small groups.
• Able to work with Customer in Mexico, Canada, and USA.

Mathematical Skills:

Thorough knowledge of SPC techniques and applications, including DOE & MSA.

Reasoning Ability:

Solid understanding of structured problem-solving methodologies, including 8D, 5W, Ishikawa (fishbone) analysis, is/is not, six-sigma, etc., with emphasis on systematic problem prevention.

General understanding of structural testing and analysis of results including determination of failure modes; ability to analyze results of structural testing failures to determine root cause and corrective action.

Other Skills and Ability:

• Working knowledge of blueprint reading, including GD&T, gauging, and measurement systems.
• Familiarity with automotive quality systems methodology and requirements, including IATF
• Demonstrated ability to provide effective quality direction to new program launch.
• Balance team and individual responsibilities; exhibit objectivity and openness to others' views; contribute to building a positive team spirit.