Position Purpose

Engineering-level quality position with supervisory responsibility for the hourly Quality team. Personally performs engineering-level problem solving and owns internal quality at the plant: internal 8Ds, nonconforming material and MRB, containment, scrap, safe launch corrective action, SPC reaction, and the measurement system analysis (MSA) system. Directly supervises the Quality Technicians, MRB Technician and Quality Inspectors, and has a dotted-line relationship with the Gage Calibration Technician for MSA and floor gauge priorities. Works as a peer to the Quality Engineers and supports customer, supplier and launch work whenever manufacturing knowledge is needed.

Primary Responsibilities (Primary Owner)

· Internal quality problems and internal 8Ds (leads root cause and corrective action; verifies effectiveness).

· MSA system: MSA plan for control-plan gauges and new gauges, study assignments, review of results and acceptance.

· MRB management and disposition within approved authority.

· Quality alerts and in-plant containment, including sorting.

· Scrap reporting and coordination of the scrap reduction plan.

· Safe launch corrective actions and SPC reaction to out-of-control conditions.

· Supervision of hourly Quality personnel: Quality Technicians, MRB Technician and Quality Inspectors.

Key Duties

· Lead internal 8Ds and root cause analysis for manufacturing quality problems using problem-solving techniques (i.e., 8D methodology, 6 sigma, DOE, 3 leg-5 why, Shainin, etc.); assign Quality Technicians and cross-functional team members; verify corrective action effectiveness.

· Ensure products conform to quality standards by taking the following actions:

o Initiate corrective action to prevent product nonconformance.

o Identify, record and manage product quality problems (NCRs and CAPAs).

o Initiate and recommend solutions through the corrective action process; verify solutions.

o Control further processing, delivery or installation of nonconforming product until it is corrected.

· Own the MSA system: maintain the MSA plan for control-plan gauges and new-program gauges, assign studies to the Gage Calibration Technician and Quality Technicians, review results, and approve or reject measurement systems (with the program Quality Engineer for new-program gauges).

· Drive manufacturing process improvements using statistical process control techniques; ensure appropriate reaction to SPC out-of-control conditions.

· Improve error and mistake proofing (poka-yoke) methods by working with multifunctional teams.

· Issue quality alerts and lead in-plant containment and sorting; coordinate with the Customer Quality Engineer when a customer is affected and with the Supplier Quality Engineer when a supplier is the suspected cause.

· Chair MRB: review nonconforming material, make dispositions within approved authority (scrap, rework to approved instructions, return to supplier), and escalate use-as-is or deviation requests to the Quality Engineers / Quality Manager.

· Oversee the MRB Technician's MRB report and rework activity; monitor MRB aging; assign Quality Technicians to MRB rework only in overflow conditions.

· Own scrap reporting; ensure scrap is analyzed and classified daily; maintain the scrap Pareto, coordinate the scrap reduction plan, and track scrap projects assigned to the Quality Engineers.

  · Lead corrective actions arising from safe launch findings; provide input to the program Quality Engineer on safe launch exit readiness.

· Follow up on Layered Process Audit findings in manufacturing; act as process owner for internal and IATF audit findings in manufacturing quality areas.

· Provide first-level escalation for production support from Inspectors and Technicians; support the Quality Engineers on customer and supplier issues that require manufacturing root cause.

· Participate in the internal audit pool once qualified; perform internal audits in accordance with IATF 16949 (not auditing own area).

· Create, review and approve Work Place Instructions / procedures within area of responsibility.

· Directly supervise hourly Quality associates: set daily priorities and work assignments, develop work schedules and overtime, authorize time and attendance, and manage absence issues, coaching and discipline as needed.

· Partner with HR to manage promotions, terminations and transfers; address and resolve employee concerns and manage conflict.

· Improve the skills of associates by providing clear performance expectations, specific feedback, coaching and mentoring, developmental opportunities, and accurate, timely performance appraisals.

· Train and develop hourly Quality employees (on-the-job training, cross-training coverage, safe work habits and good housekeeping); support Quality training events delivered by the Senior Quality Technician, including operator gauge training.

· Utilize Plex for quality transactions (holds, MRB, scrap) and ensure employees follow processes, use reporting, troubleshoot issues and fix mistakes.

· Regularly communicate with associates regarding customer, production and quality issues, overtime, and changes to procedures and processes.

· Reinforce 5S (housekeeping) behaviors and maintain good housekeeping in the work area.

· Ensure a safe working environment; follow and enforce PPE and safety procedures.

· Ensure manufacturing practices are current, consistent and compliant with GSS Policies and Procedures, all external state/federal regulations and customer requirements.

Backup / Support Responsibilities

· Supports the Customer Quality Engineer on customer RCAs (in-plant containment, data and manufacturing knowledge on the 8D team) and the Supplier Quality Engineer on supplier issues found in-plant.

· Can act as backup program quality lead for a launch program when a Quality Engineer is unavailable.

· Backed up by the Quality Manager for personnel administration and MRB disposition.

· Is not the primary owner of customer 8Ds (Customer QE) or MRB rework execution (MRB Technician). MSA studies are performed by the Gage Calibration Technician and Quality Technicians under the Supervisor's MSA plan.

Required Qualifications (Experience and Education)

· (Recommended) Bachelor's degree in Engineering, Quality or a related technical field, OR an associate technical degree with substantial quality engineering or senior quality technician experience in manufacturing.

· Minimum 3 years in a manufacturing environment (automotive-related experience preferred).

· Demonstrated leadership or supervisory experience.

· Demonstrated proficiency in root cause problem solving (8D or equivalent).

· Proficient in the use of statistical process control software (Minitab preferred) and strong computer skills (intermediate-level Excel).

Authority / Decision-Making

· Authority to stop production or shipment and place product on hold when quality is in question, and to release product within approved dispositions.

· MRB dispositions of scrap, rework to approved rework instructions, and return to supplier; use-as-is and customer deviations are escalated.

· Accepts or rejects measurement systems based on MSA results.

· Assigns and prioritizes work of hourly Quality personnel; Quality Engineers request technician support through the Supervisor.

· Approves time and attendance and overtime for direct reports; recommends hiring, discipline and termination in partnership with HR.

Key Interfaces

· Direct reports: Quality Technicians (2), MRB Technician, Quality Inspectors (3). Dotted line: Gage Calibration Technician (MSA and floor gauge priorities).

· Quality Engineers (peers): in-plant containment and root cause support for customer complaints and supplier issues; launch handoff to production.

· Senior Quality Technician: LPA findings, change control impacts on the floor, training events.

· Production supervision, Maintenance, Manufacturing Engineering and Materials.

Preferred Qualifications

· Quality Engineering Certification (CQE); six sigma training (green/black belt); lean principles.

· Plex system experience.

· (Recommended) Working knowledge of AIAG core tools, especially MSA and SPC, and nonconforming material control / MRB.

· (Recommended) IATF 16949 internal auditor training (can be completed after hire).

Competencies – Knowledge, Skills and Characteristics/Behaviors

· Influencing others, analytical thinking, high-level integrity, problem solving, self-managed.

· Effective written and verbal communication; demonstrated ability to interact with production personnel as well as management.

· Demonstrated leader and change agent focused on achieving results; ability to collaborate and drive continual improvement.

· Ability to follow the established rules, policies and practices of environmental, health and safety (OSHA).

Additional Notes

· Position requires the ability to lift and manually handle components (not to exceed 35 lbs), good hand dexterity, and daily visual inspection as required.

The above are principal responsibilities and do not identify all duties inherent in the job. Primary ownership means accountability for the activity being completed and communicated; it does not limit the position from supporting other Quality activities, and it does not prevent other positions from supporting this one.