Job Summary:

The Process Quality Engineer (PQE) is responsible for providing quality engineering support for new product release to manufacturing and for ongoing manufacturing operations. The PQE sets high standards for process performance and initiates problem solving and variation reduction activities for process control and improvement. The PQE works in a cross-functional team environment to develop and implement the best practices that emphasis defect reduction, reduction in process variation, and provide Continuous Improvement (CI) opportunities.

Supervisory Responsibilities:

• None

Duties/Responsibilities:

• Identify root cause and investigate permanent corrective actions for product quality issues
• Maintain records and investigate external complaints, drive action plans and root cause analysis.
• Compile and analyze manufacturing scrap data to drive CI.
• Lead teams in root cause investigation for manufacturing defects and CI projects are identified and addressed
• Develops solid understanding of all manufacturing processes, machinery, and equipment including how the production systems are designed to function, their limitations, and the impact of variation on thru-put, reliability, yield, and quality
• Responsible for process quality audits/sign-off on all new production equipment.

• Develop, implement, and validate measurement systems for product or process characteristics
• Collect sample data and determine process capability or need for process control
• Interact with third party auditors/representatives during inspections/audits
• Interpret analytical data and applications data

• Use statistical techniques (hypothesis testing, correlation, regression) to identify major sources of defects or variation
• Identify and formulate problem statements, develop potential solutions, prioritize actions, determine and perform the appropriate analysis, and lead efforts through resolution.

• Improve existing processes and define new processes
• Design experiments to optimize process settings and use FMEA to identify potential problems
• Implement cost-effective solutions into production, moving deviations or changes through the change control process
• Work closely with supervisors and operators to improve product flow, improve quality, and reduce scrap
• Troubleshoot existing processes to maintain or improve quality parts by the use of process controls

• Sustain improvements by developing process flow diagrams, PFMEAs, control plans, work instructions, setup documents, and other manufacturing related documentation
• Support design for manufacturing reviews and design FMEA activities, sharing lessons learned with advanced program teams
• Lead the development of training material relating to operational sequence of operation & the use of controls to regulate the process in achieving high thru-put / quality.
• Provide instruction of established processes to other process technicians and supervisors/operators.
• Maintain thorough, well documented records of all process/product monitoring activities

General Conduct

• Maintains respectful working relationship with TeamMates, Decoration and Assembly Team Leaders, Decoration Team Leaders, Production Assistants to promote teamwork and a positive work environment.
• Committed to continual Improvement to raise personal performance to meet and exceeds the standard and to develop new methods to eliminate wastes, improve productivity and reduce customer complaints.
• Maintains excellent attendance as defined in the company’s Attendance Policy.
• Supports and complies with all company policies and procedures, including safety and quality.
• Submits new ideas to improve safety, quality and procedural operations that will benefit the company.
• Actively participates in departmental meetings by providing suggestions for improvement, problem solving and offering feedback.
• Performs duties in a manner that encourages teamwork and sets a positive example.

Required Skills/Abilities:

• Must be able to acquire and analyze data using appropriate standard quantitative methods across a spectrum of business environments to facilitate process analysis and improvements
• Ability to interpret engineering drawings/schematics and use a broad range of measurement devices/gages is required
• Proficiency in Microsoft Office Suite is necessary
• Knowledge of a quality system and its development, documentation and implementation to domestic and international standards is desired
• A basic understanding of auditing processes including types of audits, planning, preparation, execution, reporting, and follow-up would be helpful
• Knowledge of lean manufacturing and/or six sigma tools and applications is preferred

Education and Experience:

• Bachelor’s Degree in Engineering (Plastics, Mechanical, or Industrial Engineering) is preferred
• ASQ Certified Quality Engineer (CQE) certification and/or Certified Quality Auditor (ISO 13485 lead auditor) would be a plus
• 3 or more years of experience is preferred including structured problem solving (for example, Lean Manufacturing, Six Sigma, PDCA, 8D) and the application of statistical techniques such as hypothesis testing and design of experiments

• A basic understanding of auditing processes including types of audits, planning, preparation, execution, reporting, and follow-up would be helpful
• Knowledge of lean manufacturing and/or six sigma tools and applications is preferred

Physical Requirements:

• Prolonged periods of standing or sitting.
• Lifting of 50 pounds maximum.