Quality Control Manager

E.S. KLUFT & COMPANY INC•Grand Prairie, TX

8h•Hybrid

About The Position

The Quality Manager is a strategic leader responsible for the entire Quality Management System, driving product excellence and continuous improvement to meet the high standards of the luxury mattress market. This role goes beyond inspection to own and enhance the culture of quality, ensuring customer satisfaction through robust processes, data-driven decisions, and a proactive approach to problem-solving. The ideal candidate will possess deep expertise in quality systems, statistical analysis, and root cause correction, with a hands-on, "roll up your sleeves" leadership style.

Requirements

Bachelor’s degree in engineering, Manufacturing, or related discipline required.
7+ years of progressive experience in Quality Management, Quality Engineering, or Process Engineering within a manufacturing environment; bedding, furniture, or textile experience strongly preferred.
Six Sigma Green Belt desired; Black Belt certification is a significant plus.
In-depth ability to understand urethane foam processes, innerspring systems, quilt assembly, and mattress construction.
Expert knowledge of relevant test standards (16 CFR 1633, ASTM D3574, ASTM F1566).
Proficiency in ERP systems (SAP preferred) for data analysis and quality module management.
Strong foundation of analytical, problem-solving, and critical thinking skills with expertise in statistical analysis.
Demonstrated experience with all MS Office products, advanced proficiency in Excel for data mining and dashboard creation.
Excellent verbal and written communication skills, with the ability to influence and lead at all levels of the organization.
Use required PPE: Safety Glasses and Safety Vest.

Nice To Haves

Six Sigma Black Belt certification is a significant plus.

Responsibilities

Own, manage, and continuously improve the Plant's Quality Management System (QMS).
Develop and implement a comprehensive quality strategy focused on process control, from raw material (foam, springs, fabric) reception to finished goods.
Lead and mentor the Quality team, including Supervisors and Inspectors, fostering a culture of accountability and excellence.
Floor Time - 50% or greater.
Analyze quality data (defect rates, returns, audit results) to identify trends, prioritize improvement projects, and report on key performance indicators (KPIs) to plant leadership.
Utilize LEAN and Six Sigma methodologies as the primary driver for reducing process variation and improving product quality.
Lead cross-functional root cause analysis and corrective action (CAR, 8Ds, A3, or CAPA) for critical quality issues, ensuring effective and sustainable solutions.
Authorize, manage, and validate all quality control plans, work instructions, and inspection criteria for all processes.
Serve as the primary site contact for all customer and third-party audits (e.g., regulatory, major retailers); prepare responses and ensure compliance.
Establish and manage the First Article Inspection (FAI) process for new products and SKUs, ensuring a smooth production launch.
Support golden samples, floor samples, and other assigned samples.
Oversee the entire product testing program, including flammability (CFR 1633), foam durability (ASTM D3574), and other performance standards.
Lead the non-conforming material process and collaborate with Supply Chain on vendor quality issues.
Drive the standardization of quality practices and communication across all shifts.
Responsible for the department's staffing, development, training, and employee relations.
Plan, execute, and participate in Product and Process audits.
Perform a daily mattress inspection audit and share the results with the relevant departments.
Write and manage work instructions for quality inspection by process, from raw material receiving to finished goods.
Develop continuous training and feedback on inspection and measurement methods.
Monitor Quality supervisor and Quality inspectors’ productivity and provide constructive feedback and coaching.
Responsible for staffing, training, and employee relations.
Provide coverage in the absence of the Quality Supervisor and Quality Inspectors as needed.
Ensure the calibration and maintenance of all test and measurement equipment.
Other duties may be assigned as needed