Process Quality Engineer

Position Summary: The Process Quality Engineer is responsible for improving manufacturing process performance, reducing defects, and increasing customer satisfaction through quality engineering, data analysis, structured problem solving, corrective action management, and continuous improvement. This position serves as the process quality subject matter expert, driving cross-functional efforts to identify systemic issues, eliminate root causes, improve process capability, and strengthen operational controls throughout manufacturing and the supply chain. The Process Quality Engineer utilizes statistical analysis, quality methodologies, and business intelligence tools to transform quality and operational data into actionable improvement initiatives. The role partners closely with Operations, Manufacturing Engineering, Supply Chain, Production, and Quality teams to improve process effectiveness, reduce variation, and ensure sustainable corrective actions that prevent recurrence. Essential Duties and Responsibilities: - Lead structured problem-solving activities using 8D, 5 Why, Fishbone Diagram, Is/Is Not Analysis, Fault Tree Analysis, and other root cause methodologies. - Facilitate cross-functional investigations involving customer complaints, internal nonconformances, supplier issues, process failures, and customer escapes. - Drive containment activities to protect customers and minimize operational impact when quality issues occur. - Identify root causes and develop effective corrective and preventive actions that address systemic process weaknesses. - Manage the corrective action system and ensure compliance with customer, regulatory, ISO 9001, and internal quality requirements. - Monitor corrective action progress, closure effectiveness, and overdue actions, escalating unresolved issues when necessary. - Verify corrective action effectiveness through audits, data analysis, record reviews, inspections, and performance metrics. - Analyze quality and operational data to identify trends, recurring issues, process variation, and improvement opportunities. - Develop, maintain, and enhance Power BI dashboards, scorecards, and key performance indicator (KPI) reports. - Track and report quality performance metrics including customer complaints, NCRs, scrap, rework, yield, supplier quality performance, corrective action closure rates, and Cost of Poor Quality (COPQ). - Prepare and present quality performance reports and trend analyses for leadership and operational review meetings. - Utilize statistical tools and methods including Pareto Analysis, Control Charts, Process Capability Studies, and trend analysis to support decision-making. - Lead process improvement initiatives focused on reducing defects, improving process capability, and enhancing operational performance. - Support implementation of Lean Manufacturing, Six Sigma, and continuous improvement methodologies throughout the organization. - Participate in APQP, PFMEA, Control Plans, First Article Inspection (FAI), PPAP, process validation, and risk assessment activities as required. - Collaborate with Manufacturing Engineering, Operations, Supply Chain, and Quality teams to improve manufacturing processes and product conformity. - Support supplier quality improvement efforts through data analysis, corrective actions, and problem-solving activities. - Identify opportunities to standardize processes, improve controls, and reduce process variation. - Assist in the development and maintenance of quality procedures, process controls, and quality documentation. - Support internal audits, management reviews, and continuous improvement initiatives related to the quality management system. - Promote a culture of quality, accountability, and data-driven decision-making throughout the organization. Key Competencies - Advanced root cause analysis and problem-solving techniques - Corrective and preventive action management - Statistical analysis and process capability evaluation - Manufacturing process improvement - Power BI dashboard development and reporting - Quality systems and ISO 9001 requirements - Lean Manufacturing and Six Sigma methodologies - Data analytics and KPI management - Facilitation of cross-functional improvement teams - Project management and change implementation - Strong communication and presentation skills - Ability to influence and drive accountability across all organizational levels Education and Experience: - Bachelor's degree in Quality Engineering, Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or a related technical field. - Minimum three (3) years of experience in Quality Engineering, Process Engineering, Manufacturing Engineering, or a related role. - Experience leading root cause investigations and corrective action programs in a manufacturing environment. - Proficiency with Microsoft Power BI including dashboard creation, KPI reporting, data modeling, and trend analysis. - Experience analyzing large datasets and converting findings into actionable process improvements. - Knowledge of statistical methods including SPC, Pareto Analysis, Control Charts, Process Capability Studies, and Measurement System Analysis (MSA). - Experience with Lean Manufacturing, Kaizen, Six Sigma, and continuous improvement methodologies. - Lean Six Sigma Green Belt or higher preferred. - ASQ Certified Quality Engineer (CQE), Certified Quality Auditor (CQA), or equivalent certification preferred. - Experience in metal fabrication, machining, welding, assembly, or high-mix manufacturing environments preferred. - Working knowledge of APQP, PFMEA, Control Plans, FAI, PPAP, and risk-based quality tools. - Strong facilitation skills with the ability to lead cross-functional teams through quality and process improvement initiatives. - Experience working within ISO 9001 or similar quality management systems. Physical Requirements - Ability to work in both office and manufacturing environments. - Ability to stand, walk, bend, climb, and inspect production processes and equipment. - Ability to safely work around manufacturing equipment, machinery, material handling equipment, and production operations. - Ability to occasionally lift up to 50 pounds with or without reasonable accommodation. - Ability to wear required personal protective equipment (PPE) and access production areas as needed. - Ability to concentrate and remain focused in an open office environment with potential distractions - Occasional travel may be required for training or coordination with other VDL locations.