Quality Engineer

• Job Category Engineering
• Employee Type Full Time Regular
• Manage Others No

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In plastic manufacturing, quality isn’t just a metric. It’s the difference between a flawless part and a costly recall, a satisfied customer and a missed opportunity. If you’re someone who can spot a molding defect before the press even cools, who loves dialing in processes until they run like clockwork, and who thrives in a fast-paced production environment, we want you on our team.

This is 100% onsite in Baraboo, Wisconsin.

• Utilize documented information (provided by the customer) to understand the Voice of the Customer, and effectively communicate these requirements to responsible parties during the Quotation process.
• Create new, and update existing, master production work instructions (i.e. OQRs, Pack Cards, etc).
• [For contract manufacturing] In accordance with the customer provided DFMEA, lead the cross-functional team to create and update the associated PFMEA for the production process.
• [For products that Flambeau is Design responsible for] Provide input/work with the team to develop the DFMEA. In accordance with the DFMEA, create and update the associated PFMEA for the production process.
• In accordance with the PFMEA, create and update the associated Control Plan for the product.
• [Whether for contract manufacturing or Design responsible products] In accordance with the PFMEA, create and update the associated Control Plan by properly identifying the Critical Control Points in the process.
• Generate and approve applicable Deviations and Waivers.
• Investigate and provide disposition (approve/deny) for potential external failures (i.e. Customer Complaints & Warranty Claims).
• Conduct required Risk Assessments associated with internal (NCs/MRBs) and/or external failures (Customer Complaints) to determine if product can be used as is, can be reworked/sorted, or must be scrapped.
• Based on the risk assessment, if the product can be reworked/sorted, provide guidance on the rework “Plan” phase (of PDCA).
• Conduct the “Bracketing Rationale” using data/evidence to support the Containment plan for external (i.e. Customer Complaints) failures.
• Construct the “timeline of production” (i.e. the story of how it happened, not why it happened) for confirmed external failures (i.e. Customer Complaints), to feed into Root Cause Analysis.
• If a Confirmed Complaint (if applicable), issue a Return Material Authorization (RMA) to the customer.
• Facilitate the cross-functional investigation to determine Root Cause of Internal (i.e. NCs/MRBs) and External failures (i.e. Customer Complaints).
• Facilitate the cross-functional Brainstorming of Action Items to specifically address the identified Root Cause.
• Qualify new, and changes to existing, manufacturing processes (i.e. which may involve PPAP submissions for Automotive customers).
• Generating new, and updating existing, Standard Operating Procedures (SOPs)
• Assisting with External Audits (i.e. customer, regulatory, etc), as necessary.
• Effectively communicate and build relationships with customers to facilitate resolution of quality issues. Visit customers as needed to maintain relationships and resolve issues.
• All other duties assigned by Manager

• B.S. degree in Engineering (Mechanical, Industrial, Manufacturing) or related field of Science, or an equivalent combination of education, training, and experience.
• Good Dimensioning and Tolerancing (GD&T) is preferred.

• Experience with business management systems certified to ISO 9001 and/or IATF 16949 required.
• 3 – 5 years’ experience in plastics manufacturing preferred.

• Ability to work independently, as well as with cross-functional teams.
• Critical Thinking
• Problem Solving (i.e. Root Cause Analysis)
• Knowledge of various measurement tools/methods, GD&T, and CMM layouts.
• Data…