Advanced Quality Analyst II

Lear Corporation•Duncan, SC

9d•Onsite

About The Position

As a member of the quality team, the Quality Analyst II will be responsible for leading manufacturing location APQP deliverables and confirming completion of the site's quality documents required internally and by the customer during the initial launch phases of a product leading up to PPAP. This role acts as a liaison for all Advanced Product Quality Planning (APQP) activities, including internal gate reviews with the customer and internal program team. The Quality Analyst II ensures customer requirements are incorporated into product functional specifications and included in the Control Plan, and supports PFMEA activities to ensure functional specification requirements are fully met. This position also coordinates with Industrial Engineering on the development and implementation of Poka Yoke strategies and supports/attends launch program customer meetings and customer process reviews/audits. The role monitors Run-at-Rate activities and process run documentation, attends customer-initiated quality meetings, and ensures manufacturing location documentation complies with Lear Program Management System requirements. The Quality Analyst II coordinates the development of the Production Process Control Plan and Safe Launch Plan, and updates the Control Plan until formal Start of Production (SOP). They also coordinate and actively participate in customer visits related to quality activities, coach and support the manufacturing team on customer product quality requirements and site APQP requirements, and monitor the approval of supplied components. The role conducts APQP program gate reviews, reviews and participates in design reviews and manufacturing feasibility activities, and exercises authority to stop any process or product delivery in cases of customer non-conformance, safety concerns, or environmental risks. Additionally, the Quality Analyst II supports plant production by ensuring all supplier parts meet engineering requirements, manages supplier notifications, responsiveness, containment actions, root cause investigations, corrective actions, and closure of supplier quality issues. They track supplier-related costs associated with poor quality and/or service, serve as owner of the receiving and inspection process, provide weekly summaries on Quality Notification (QN) status, chargebacks, and sorting status, and facilitate and supervise all supplier-based sorting and product containment activities. The role also processes parts placed in quarantine and performs all other duties as assigned.

Requirements

Strong communication and coordination skills.
Expertise in the calibration of test equipment.
Expertise in performing tests within the scope of the laboratory.
Expertise in statistical methods.
Expert problem-solving and analytical skills using 8D methodology, including: Is / Is Not Analysis, Fishbone Diagram, Brainstorming, Affinity Diagrams, Three-Legged 5 Why Analysis.
Competent in quality tools and process/production control methods, including: APQP (Advanced Product Quality Planning), Control Plan, PFMEA (Process Failure Mode and Effects Analysis), GD&T (Geometric Dimensioning and Tolerancing), MSA (Measurement Systems Analysis), SPC (Statistical Process Control).
Ability to read and interpret engineering drawings to understand agreed quality parameters and product-specific requirements.

Nice To Haves

Knowledge of customer-specific requirements.
Proficiency with Microsoft Office Applications

Responsibilities

Lead manufacturing location APQP deliverables and confirm completion of the site's quality documents required internally and by the customer during the initial launch phases of a product leading up to PPAP.
Act as liaison for all Advanced Product Quality Planning (APQP) activities, including internal gate reviews with the customer and internal program team.
Ensure customer requirements are incorporated into product functional specifications and included in the Control Plan.
Support PFMEA activities to ensure functional specification requirements are fully met and confirm controls are carried into the Control Plan.
Coordinate with Industrial Engineering on the development and implementation of Poka Yoke strategies and confirm controls are carried into the Control Plan.
Support and attend launch program customer meetings and customer process reviews/audits.
Monitor Run-at-Rate activities and process run documentation.
Attend all customer-initiated regular and ad hoc quality meetings representing the organization.
Ensure manufacturing location documentation complies with Lear Program Management System requirements.
Coordinate the development of the Production Process Control Plan and Safe Launch Plan, and update the Control Plan until formal Start of Production (SOP).
Coordinate and actively participate in customer visits related to quality activities.
Coach and support the manufacturing team on customer product quality requirements and site APQP requirements.
Monitor approval of supplied components.
Conduct APQP program gate reviews to confirm activities are complete, evidence is available, readiness assessments are completed, and all site APQP documents are submitted on time and loaded into the Lear Program Management System.
Review and participate in design reviews and manufacturing feasibility activities.
Exercise authority and responsibility to stop any process or product delivery in cases of customer non-conformance, safety concerns, or environmental risks.
Support plant production by ensuring all supplier parts meet engineering requirements.
Manage supplier notifications, responsiveness, containment actions, root cause investigations, corrective actions, and closure of supplier quality issues using the internal supplier tracking database.
Track supplier-related costs associated with poor quality and/or service, summarize costs, and communicate them to suppliers through the debit memo process.
Serve as owner of the receiving and inspection process, including supervision of Incoming Inspectors and maintenance of incoming inspection reports, data, and records.
Provide weekly summaries on Quality Notification (QN) status, chargebacks, and sorting status.
Facilitate and supervise all supplier-based sorting and product containment activities.
Process parts placed in quarantine.
Perform all other duties as assigned.