Advanced Quality Engineer

Postion: Advanced Quality Engineer

Position Summary: The Advanced Quality Engineer (AQE) plays a key role in ensuring that new and existing products meet Rotor Clip’s high standards for quality, safety, and performance. This position will lead new product introduction (NPI) quality activities, develop advanced quality plans, and partner with cross-functional teams to drive process capability and defect prevention in a custom, high-mix ring manufacturing environment. This position works closely with the Engineering Team to ensure manufacturing processes are designed to meet customer quality requirements.

The ideal candidate has hands-on experience supporting fabrication, welding, assembly, and mechanical/electrical integration, along with a strong understanding of APQP, PPAP, FMEA, and control plan development.

Main tasks, duties, authorization limits and deputy functions:

1. Lead Advanced Product Quality Planning (APQP) activities for new product introduction and engineering changes, ensuring manufacturability and quality readiness.
2. Develop and maintain Control Plans, FMEAs, Process Flow Diagrams, and Inspection Standards for new and existing products.
3. Identify critical dimensions and features with customer input, define input variables to control, develop tooling and methodologies to measure features, build systems to record and track measurements, ensure capability to implement SPC in processes.
4. Collaborate with Engineering, Manufacturing, and Supply Chain during the design and prototype phases to identify potential quality risks and implement preventative measures.
5. Establish and validate process capability (Cp, Cpk) for key manufacturing operations, including steel fabrication, welding, machining, and assembly.
6. Drive First Article Inspection (FAI) and Production Part Approval Process (PPAP) documentation for new or modified parts and assemblies.
7. Directly responsible for ensuring all quality standards for products are met prior to shipment to customer.
8. Uses advanced problem solving skills to Investigate, conducts tests or experiments in resolving product performance issues. Conducts thorough root cause investigation and is responsible to drive implementation of corrective action and preventive measures.
9. Directly responsible for customer complaint reduction of Rotor Clip products.
10. Perform verification and effectiveness reviews of corrective actions
11. Makes independent risk based decision when faced with releasing non-conforming products.
12. Participate in ongoing process improvement efforts to ensure design, manufacturing and quality methodologies are effective, efficient, standardized and integrated.
13. Employ 8D 5Why's and other Lean tools to enhance Quality and productivity. Participate in Lean activities including Kaizen events, 5S audits.
14. Initiate and lead efforts in implementing poka-yoke tools and fixtures in production line to build quality products which eliminate customer complaints.
15. Evaluate our current-state approach and results, and define and implement innovative approaches to improve quality through the introduction of new technologies, systems, methods and controls.
16. Support efforts to facilitate quality systems compliance and certifications.
17. Compiles and writes training material, SOP’s, and QC Criteria as required.
18. Conduct internal Quality system audits and be involved with CAPA projects.
19. Provide technical training and guidance to technicians and operators on quality methods and measurement techniques.

Education/Experience:

1. Bachelor’s degree in Mechanical, Industrial, Manufacturing Engineering, or related field.
2. Minimum of 3 years’ experience in a Quality Engineering oriented role, within a manufacturing environment that is certified to IATF 16949 or AS9100.
3. ASQ Certified Quality Engineer a plus
4. Six Sigma Green Belt or Black Belt certification a plus

Skills:

1. Demonstrated success leading NPI and APQP processes.
2. Hands-on experience developing and maintaining Control Plans, FMEAs, and PPAP documentation.
3. Proficiency in root cause analysis tools (8D, 5 Why, Fishbone, DMAIC).
4. Working knowledge of IATF 16949 or equivalent quality management systems.
5. Solid communication skills, able to work effectively in cross functional teams.
6. Ability to read and understand engineering drawings including GD&T. Experience in Solid works or Catia is a plus.
7. Excellent interpersonal skills to lead teams and drive projects to successful closure.
8. Demonstrate accuracy, attention to detail and ability to work well in team environment.
9. Exercise initiative, achievement and independent judgment.
10. High ability to multi-task and perform under pressure

Working Conditions:

1. Full-time, on-site position based in Somerset, NJ.
2. Work performed in both office and manufacturing floor environments.

Occasional travel to other Rotor Clip facilities, suppliers, or customer sites may be