Senior Engineer - Plant Quality (Machining) 6928 in Gray Court, SC at ZF

Date Posted: 8/22/2018

Job Snapshot

Job Description

Senior Engineer - Plant Quality (Machining) 6928


Position Summary:
The primary role will be to coordinate technical solutions related to Machining Quality Processes as well as a first responder to quality issues in the production. Associated responsibility is to promote and ensure product quality and promote Quality culture and customer satisfaction.

Position Responsibilities:

• Supports and complies with established Company’s Corporate Principles and goals.
• Understand and comply with Quality requirements such as ISO 14000 and IATF 16949 requirements
• Monitor manufacturing processes and assess product quality to determine adequacy, capability and ability to comply with customer specifications and company’s specifications.
• Develop and maintain documents and procedures related to quality standards, risk analysis, lessons learned from product recalls, product audits, field returns and repairs, complaints, scrap, and rework, and retain documented information as evidence.
• Capability to interpret prints and measurement tools (GD&T).
• Provide guidance to manufacturing personnel in the proper application of quality systems and tools.
• Utilize basic quality tools along with problem solving and lean manufacturing techniques in the support of continuous improvement, root cause analysis, corrective/preventive actions promoting lessons learned process.
• Perform activities in coordination with other departments, effectively respond and communicate in a timely manner. Developing and maintaining productive working relationships.
• Able to lead cross-functional working groups and drive the conclusion of activities. 
• Initiate, complete and ensure proper conformity of engineering changes to quality standards.
• Self-driven to trigger additional escalation levels as needed in order to protect internal and external customer.
• To have an auditor perspective including being part of the solution.
• Work on other duties and special projects as it relates to the position.

Specific Responsibilities:

• Collaborate with Customer Quality Engineer, Product and Manufacturing Engineering personnel to determine critical part features and review manufacturability of design.  Make recommendations to modify customer part specifications and tolerances as necessary to support cost effective production.
• Participate in the Advanced Product Quality Planning activities to determine appropriate use of existing and new measurement systems during new tool or process design and startup.
• Participate in the development of Failure Mode and Effects Analysis (FMEA).
• Assure Control Plans are available and updated throughout the life of the part.
• Coordinate general activities of Quality Engineers I and II. Another line contains this responsibility.
• Collaborate to Develop and submit PPAP documents for new product launches and revision of current products to meet customer requirements.
• Apply appropriate use of statistical techniques.
• Determine when process stability and capability studies should be performed on existing processes.  Review and analyze results.  Recommend changes to processes based upon findings and perform follow up to verify effectiveness.
• Determine and Perform validation of new and existing error and mistake proofing devices.
• Determine and Perform evaluation of product and process change requests.
• Determine and apply appropriate Measurement System Analysis tools.
• Resolve quality issues of capability, tolerancing, and materials related issues.
• Resolve quality issues by identifying problems, examining solution options, implementing action plans, and providing resources.
• Facilitate and promote use of appropriate problem solving techniques for effective root cause analysis and successful corrective action.
• Coordinate pre-launch production trial run process monitoring.
• Monitor costs and KPIs associated to product non-quality, propose and lead improvement plans to achieve Company’s goals.
• Audit the processes per ZF, Customers and International Associations Standards. Guide and respond to external auditors.
• Elaborate and Approve Quality Reports as needed
• Coordinate and Define priorities for general activities of Quality Engineers I, II and III.
• Provide Coaching and mentoring to levels I, II and III based on ZF competences.
• Support Area manager on personnel process evaluation, as well as hiring and separation processes.
• Processing of stop notes.

Essential Skills and Experience:

• Bachelor’s degree in a technical subject
• 7+ years of related progressive experience in a manufacturing or technical environment
• 2+ years of experience in quality related role
• Strong knowledge in problem solving methodology and techniques.
• Ability to train others.
• Deep knowledge of manufacturing systems or related technology
• Proven ability to make recommendations to effectively resolve problems or issues, by using judgment that is in consistent with standards, practices, policies, procedures
• Proficient with Microsoft Office (e.g. Excel, Access, Word, PowerPoint, etc.)
• Proven creativity and analytical methods (i.e. six sigma ) with a high-level of attention to detail
• Ability to interface with cross-functional teams and all levels of personnel and management
• Excellent verbal and written communication skills
• Excellent English language competency – both written and oral
• Excellent presentation skills

Preferred Skills and experience:

• Master in Engineering
• Expert level in Transmission assembly and/or high volume assembly in automotive environment
• Experience of problem solving methodologies
• Internal/external Auditor Certification
• Experience of problem solving methodologies
• Shainin/Six Sigma training
• German language skills

Reporting to Position: N/A


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