Quality Engineer

Overview

Position

Description:

Resolve non-conforming parts issues for EJOT ATF customers.

Customers encounter parts that sometimes do not meet written or unwritten product requirements. This role requires containment and quick resolution of issues, considering customer perspective on severity of the problem and collaborating with suppliers to implement corrective actions.

• 1. Define / Identify
  • 1.1 Receive customer notifications via any means chosen by customer.
  • 1.2 Log issue into customer complaints tracking database.
  • 1.3 Organize response including:
    • 1.3.1 Determine containment condition to stop the defect from reaching the customer.
    • 1.3.2 Complete containment activities: create quality alerts, define sorting criteria, organize sorting activity, certify sorted product, define a clean point.
    • 1.3.3 Define problem statement to supplier through SCAR initiation (as needed).
• 2. Measure
  • 2.1 Collect data, facts, findings for root cause analysis.
  • 2.2 Determine conditions unique to the work order/part when defect created.
  • 2.3 Update PFMEA based on findings.
  • 2.4 Track containment costs to forward to supplier upon issue resolution (as needed).
• 3. Analyze
  • 3.1 Use data from Gainseeker, tooling software, final inspection and quality concerns log.
  • 3.2 Formalize a team with engineering and manufacturing to determine root cause, escalating as needed.
  • 3.3 Use Fishbone and functional analysis to determine root cause.
  • 3.3.1 Investigate multiple root causes and create variation models.
  • 3.4 Devise tests and experiments to validate root cause.
  • 3.5 For supplier-controlled processes:
    • 3.5.1 Formalize team with supplier for root cause determination, escalating as needed.
    • 3.5.2 Devise tests to validate supplier root cause (may require supplier on-site visit).
• 4. Improve
  • 4.1 Determine corrective action or improvement to the process.
  • 4.2 Formalize a team with engineering and manufacturing to implement corrective action, escalating as needed.
  • 4.3 Create plan for implementation of corrective action.
  • 4.4 For supplier-controlled processes:
    • 4.4.1 Formalize team with supplier to implement corrective action.
    • 4.4.2 Follow up on corrective action implementation at supplier.
• 5. Control
  • 5.1 Define controls to ensure improved process continues to operate as intended.
  • 5.2 Formalize team with engineering/mfg to implement new controls.
  • 5.3 Determine clean point for customer with applied corrective action.
  • 5.4 For supplier-controlled processes:
    • 5.4.1 Guide supplier in defining controls.
    • 5.4.2 Formalize team with supplier to implement new controls.
    • 5.4.3 Determine clean point from supplier and customer with corrective action.
• 6. Verify Controls
  • 6.1 Create and manage verification of corrective action.
  • 6.2 Define duration of certification sort to validate effectiveness.
  • 6.3 Measure updated occurrence and detection.
  • 6.4 Update PFMEA and control plans or transfer info to PPAP team.
  • 6.5 For supplier-controlled processes:
    • 6.5.1 Follow up on verification of corrective action.
    • 6.5.2 Define duration of certification sort.
    • 6.5.3 Guide supplier to measure updated occurrence etc and update PFMEA.

Required Travel:
Up to 10%

Education & Experience:

• Bachelor of Science in Engineering
• Experience in a manufacturing environment involving forming metal and plastics (non-assembly-based operations)
• Experience in automotive industry preferred。
• 5+ years of experience in manufacturing environment。

• Cold Forming 101
• Fastener manufacturing processes – baseline knowledge of heading, rolling, heat treatment, plating, thread masking/patching, sorting, and packaging.
• Baseline function and use case for PFMEAs and Control Plans.
• Material Flow in cold state.
• Use of problem solving tools:
  Fishbone, 5
  
  Why.
• DMAIC process.
• Statistical analysis tools (model development, regression analysis, Cp/K analysis, ANOVA).
• Customer applications of ATF parts.
• Internal ATF systems – CMS procedures and material flow for disposition decisions.

• Excellent communication skills; concise description of problem and status.
• Proficiency with MINITAB for statistical analysis.
• Proficiency in problem-solving tools:
  Fishbone, 5
  
  WHY.
• Ability to measure parts, compile and analyze data.
• Proficiency with Microsoft Office Suite.
• Pr…