Lead Quality Assurance Engineer

2 weeks ago

Grand Haven, Michigan, United States Shape Corp Full time

Job Overview

Position Summary: Accountable for the creation of quality documentation, driving continuous enhancements, and collaborating with suppliers and clients to address quality or system challenges.

Key Responsibilities include, but are not limited to, the following:

General Responsibilities:

  • Generate APQP documentation to facilitate the Product Realization Process in alignment with client specifications, such as FMEA, MSA, SPC, PPAP, etc.
  • Uphold necessary documentation that adheres to Shape Corp's standards for Document Control and accessibility.
  • Engage with client representatives and assist in resolving quality concerns and issues.
  • Contribute to the development and upkeep of formal quality systems, such as ISO 9001 and IATF 16949.
  • Propel continuous improvement and the sharing of best practices within our quality systems and processes.
  • Lead problem-solving initiatives for intricate issues utilizing advanced quality methodologies.
  • Assist in onboarding and training new team members.
  • Offer guidance and mentorship to junior team members.
  • Identify and train backups to manage essential tasks during absences.
  • Undertake additional responsibilities as assigned by leadership.
  • Approve time and attendance for direct reports.
  • Review and respond to employee suggestions through the internal system.

Launch Quality Responsibilities:

  • Strategize, support, and execute total quality management to achieve zero safe launch findings at pre and post SOP.
  • Ensure that suitable inspection and containment plans are established for the process value stream.
  • Validate product quality through confirmation phase exit.
  • Initiate control plans and training for inspection and gage instructions according to Shape and client-specific requirements.
  • Develop and manage all APQP documents through PPAP approval for new program launches.
  • Execute PPAP submissions and approvals as needed for client-initiated product modifications.
  • Comprehend and interpret client-specific requirements.
  • Participate in GD&T development through the DFM process.
  • Oversee all aspects of gage procurement, including quoting, design approval, and client approval.
  • Manage supplier gage design approval, PPAP review, and approval.

New Business Pursuit Quality Responsibilities:

  • Possess a strong understanding of GD&T and its application.
  • Exhibit a high level of knowledge in KDCs, SPC, MSA, and AIAG processes.
  • Engage in all Process Plan and Tolerance Assessment Reviews.
  • Create Red Pen Fixture Drawings.
  • Contribute to GD&T development through the DFM process.
  • Author measurement plans as part of the DFM Plan.
  • Ensure appropriate inspection and containment plans are established for the process value stream.
  • Estimate gage costs for all programs, considering Shape's and each client's specifications.

Manufacturing Quality Responsibilities:

  • Ensure adherence to process control plan requirements.
  • Lead problem-solving efforts related to production quality challenges.
  • Initiate actions to overcome obstacles as they arise and prevent potential quality issues using problem-solving tools.
  • Implement interim and containment countermeasures related to quality challenges.
  • Design, specify, and implement quality control sampling systems, testing mechanisms, and equipment.
  • Act as a liaison and coordinate activities with external providers as necessary.

Supplier Quality Responsibilities:

  • Facilitate activities with external providers concerning quality challenges.
  • Liaise with launch or manufacturing quality when suppliers notify of actual or potential quality issues.
  • Collaborate with external provider personnel to resolve quality concerns.
  • Ensure external provider interim and containment countermeasures for quality issues.
  • Work with Shape quality department to promote product and system continuous improvement activities with external providers.
  • Communicate Shape quality standards to external providers.
  • Provide training and development opportunities to external providers in support of Shape and client-specific requirements.
  • Monitor supplier performance and facilitate development plans.
  • Conduct assessments and audits of external providers according to ISO 9001, IATF 16949, and client-specific requirements.
  • Contribute to the selection process of external providers.

Qualifications

Position Skills and Experience Requirements:
To successfully perform this role, an individual must be able to execute each essential duty effectively. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform essential job functions.

  • Bachelor's degree in Engineering or a related field is required. Equivalent work experience may be considered in lieu of a degree.
  • A minimum of 5 years of experience as a Quality Engineer, preferably in an automotive manufacturing setting.
  • Advanced understanding of GD&T and tolerance stack-up applications.
  • In-depth knowledge of customer-specific Program Development, such as AIAG Automotive Core Tools.
  • Familiarity with Quality Management Systems, such as ISO 9001, TS16949, and IATF 16949.
  • Experience with Product Warranty documentation.
  • Proven track record of mentoring other Quality Engineering team members.
  • Advanced project management skills utilizing Microsoft applications.
  • Strong verbal and written communication abilities.
  • Demonstrated proficiency in the use of problem-solving tools, such as 5 Whys, 8D, Ishikawa Diagram, Root Cause Analysis, etc.
  • Willingness to travel domestically and internationally as required.

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