Quality Control Engineer

Industry:

Company: Toyota Boshoku America

I. General Summary: To plan, develop, implement quality systems to ensure plant parts meet or exceed customer expectations. Responsible for investigating, analyzing, containing, and correcting quality problems related to internal / final customer products. This position may also perform audits and implement new strategies to improve the condition of plant quality.

II. Essential Job Functions:

A. Serve as liaison between plant and its customers/suppliers providing quality related technical assistance in the investigation, containment, and resolution of quality problems.

B. Coordinate each phase of the quality control/assurance activities of new and existing projects to ensure product quality, schedules, and time frames meet customer requirements and approvals.

1. Collect information and research data related to quality standard requirements to comply with customer requirements.

2. Analyze and provide input regarding quality of raw materials, purchased parts, and other items required to manufacture automotive power-train or parts and components.

3. Review material lists of conformance to company standard practices in regard to parts and materials used.

4. Analyze processes for improvements, failure modes, stability, and capability.

5. Coordinate process change requests and Engineering Change Instruction (ECI) implementation related to quality assurance activities including preparing supporting documentation, change point tracking, communications, sample part reviews, and scheduling trial parts.

6. Ensure that any new inspection equipment for the product/process is approved and maintained in the calibration system.

C. Work with the Manufacturing department to initiate effective containment, investigation, and countermeasure activities to prevent further outflow in-house and to customer.

D. Conduct quality audits including performing vehicle (end use applications) evaluations, problem analysis, and providing design/redesign input.

E. Manage and maintain quality assurance documents including quality assurance plan, tool progress report, evaluation plan, inspection standards, supplier and customer quality standards, Supplier Quality Assurance Manual (SQAM), Quality Assurance Standards (QAS), Process Flow, Process Failure Mode Effects Analysis (PFMEA), Manufacturing Quality Chart/Control Plan (MQC/CP), Initial Sample Inspection Report (ISIR), etc. Including following and obtaining customer process / approvals.

F. Support and assist with planning, development, and implementation of quality systems and activities with suppliers to ensure supplier parts meet or exceed plant and customer expectations.

G. Oversee and support service part quality issues and warranty claims as necessary.

H. Assist in developing quality management system (e.g., IATF 16949) based procedures and instructions.

I. Initiate, prepare, and present plans for quality improvements and train required team members.

J. Complete miscellaneous reporting, administrative, and other quality related functions for the Quality Control department as required including QC Circle participation, Key Performance Indicator (KPI) reporting, quality dojo creation/training, and launch document preparation, core team support etc.

K. Follow safety, quality, confidentiality, and information security policies and procedures.

III. Minimum Qualifications/Requirements:

Education:
• Bachelor’s degree in Engineering, or related field required; or an equivalent combination of

education and experience.
• Additional trade education and Quality certifications are preferred.

Experience:
• Greater than four (4) years of relevant experience and academic preparation or eight (8) years of relevant experience.
• Quality Control program launch experience for new programs preferred.
• Automotive Experience Preferred with Toyota launch systems
• Experience with manufacturing processes, tooling, quality control methods, and statistical process control (SPC).
• Injection Molding of Plastics and Urethane Molding process experience are a plus.
• Experience with measurements skill and knowledge or various quality measuring equipment is a plus.
• Leading Problem Solving Activities and using tools is a must with formal customer reporting
• Previous exposure to a multicultural office environment preferred.

Personal/Technical Skills:
• Working knowledge of quality audit techniques.
• Must be trusted with confidential data.
• Basic shop math ability required (i.e., addition, subtraction, multiplication, division).
• Understanding of conceptual math (i.e., basic geometry, charts and graphs) required.
• General understanding and working knowledge of product design specifications functions and quality standards of finished product as well as parts/materials used.
• Thorough understanding and working knowledge of automotive plants and processes, company products, trade terminology, quality management and control systems and techniques, manufacturing processes, tooling and equipment, and machine operation.
• Ability to read, interpret, and understand engineering documents such as automotive drawings (component, assembly, and equipment), technical standards, design specifications, general tolerances, critical characteristics, Geometric Dimensioning and Tolerancing (GD&T), Engineering Change Instructions (ECI), Appearance Report Requests (AR).
• General understanding of the Toyota Supplier Quality Assurance Manual (SQAM) and Toyota Production System (TPS) is preferred.
• Good presentation skills. (Internal & Customer Meetings)
• Effective time management skills.
• Ability to work in a team environment.
• Strong organization and planning skills.
• Excellent critical thinking skills required.
• Good assertiveness and negotiation skills.
• Ability to understand and create inspection standards.
• Hands-on, self-starter with a strong work ethic.
• Active listener with effective communication skills.
• Ability to compile effective and concise visual reports.
• Ability to perform responsibilities with minimal supervision.
• Ability to work in a fast-paced, multicultural work environment.
• Ability to maintain records and files and prepare recaps and reports.
• Ability to maintain on call flexibility to control abnormal conditions.
• Ability to be flexible in a constantly changing production environment.
• Ability to communicate and work well with all levels of the organization.
• Ability to create excellent working relationships with internal and external customers.
• Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.
• Ability to multitask and facilitate effective problem solving and resolution.

Language Skills:
• Strong verbal and written communication skills in English.
• Japanese is a plus.

Computer/Software:
• Solid working knowledge and experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Outlook, Internet, Newton, NEC, etc.).
• AutoCAD experience is desirable.

IV. Work Environment/Conditions:

Office: Open Office Environment, moderate noise level.

Plant: Standard automotive plant environment with moderate noise level. PPE (Personal Protective Equipment) such as safety glasses, steel toe shoes, hearing protection, etc. may be required in engineering, manufacturing, or industrial areas. Personal attire standards may apply.

Travel: Must be willing to travel up to 10% of the time to TBDN, Supplier, and Customer plants. Travel with short notice may be required.

V. Physical Demands: Ability to sit and work on a computer for extensive periods of time is required. While performing the duties of this job, the team member is required to talk, see, and hear. The team member must be capable of walking, sitting, and standing for extended periods of time. May be occasionally required to lift up to 30 pounds.

Disclaimer: This job description is intended to identify the general nature and level of work performed by team members within this classification, as well as certain essential job functions. It is not intended, and should not be interpreted, as a comprehensive inventory of all duties, responsibilities, and qualifications required of team members assigned to this job. To qualify for this job, however, a team member must be able to perform its essential functions with or without reasonable accommodation. Under no circumstances may this job description be construed as altering the at-will nature of the employment relationship between TBA and any team member.

EOE