Quality Projects Engineer III (Team Lead)

Recaro Aircraft Seating Americas•Ft Worth, TX

13d

About The Position

Performs quality control inspections, checks, and tests during the manufacture of products. Inspects materials, parts and products at different stages of production. Records observations and drives changes/ recommendations for improving processes. Responsible for timely completion of program launch deliverables. Plans and supervises daily activities of quality project engineers, and measurement technicians to ensure adherence to established department, organization, and customer specification parameters. Ensures customer requirements are understood and communicated to the departments. Works with cross-functional teams (department and site) to address customers concerns from containment through the implementation of corrective/preventive actions. Reviews existing data from past programs’ customer reviews, and provides feedback to the program team for improvement and risk mitigation for HoV programs. Acts as the focal for Quality aspects (receiving inspection/FAI parts, supplier approval, FAI/CSI, test conformity, hand-over to process quality engineers) for assigned HoV programs. Reviews and approves Design Change Proposals for seat programs, conforming to RECARO Quality System. Reviews and approves effectivity lists for HoV programs. Conducts daily shop floor meetings with the quality projects team, to oversee progress, and address deviations, and plan risk mitigation on on-going projects. Responsible for workload planning and resource allocation for quality projects engineers, and measurement team. Responsible for all personnel issues and performance evaluations of direct reports, including performance management, identifying training needs, capacity building and succession planning. Develops and maintains quality statistics, charts defects and non-conformities utilizing computer system. Maintains all relevant documentation. Performs internal audit of the FAI/CSI process, and continually improves the processes. Coordinates preparation and approval of commitment letters for deviations related to customer requirements on assigned HoV programs. Prepares Quality Inspection Dossiers, for deviations from RECARO standards, and/or per customer requirements for HoV programs. Establishes quality control plans for customer programs and ensures final product meets the required control plans. Records and resolves deviations. Acts as a liaison between customer program activities to final/ source inspectors to ensure final product meets the quality requirements of customer, regulatory authorities, OEM and internal specifications. Analyzes and assists in driving the DPU (Defects per Unit) reduction along with production team. Liaises with OEM (Airbus and Boeing) inspection to reduce factory defects found at OEM facility. Performs Quality inspections in a manner that ensures all quality and production standards are met and the final product meets RECARO engineering specifications, customer, and regulatory requirements (FAA, EASA, LBA, and other CAA) and OEM (Airbus and Boeing) specifications. Assists and offers solutions for the successful resolution of quality issues. Suggests new and improved methods for continuous improvement of the quality management system. Maintains quality statistics, charts defects and nonconformities utilizing computer system. Maintains all relevant documentation. Is a Material Review Board (MRB) member, calls MRB Meeting and is part of the decision making process. Prepares periodic reports pertaining to quality issues and their resolution from First Article Inspection (FAI) and Customer Seat Inspection (CSI). As needed, calls MRB Meeting and is part of the decision making process. Prepares reports pertaining to quality issues and their resolution. Initiates quality documentation as required concerning issues of assembly and/or materials. Moderate to heavy use in SAP and CDB. Coordinates closely with other RECARO sites to ensure consistency with practices, procedures and specifications. Supports Lean and 5S initiatives. Participates actively in continuous improvement program and corrective action projects, contributing by leading specific improvement activities. Performs root cause analysis of defects data and drives improvements. Assists and implements solutions for the successful resolution of quality issues. Suggests new and improved methods for continuous improvement of the quality management system. Maintains complete knowledge of the Quality Management Manual and relevant procedures and follows all guidelines as defined by ISO9001/AS9100, Airbus and Boeing requirements, customer requirements, FAA and other regulatory authorities. Performs First Article Inspection (Inspection & Measurement) on seats and prepares documentation in accordance with AS9102/ISO-9102. Creates MRBs to document non-conformities observed during final inspection, and first article inspection of the seat assembly and implements solutions. Performs conformity inspection on test articles (seats and flammability test coupons). Performs periodic review of the internal seat First Article Inspection (FAI) and Customer Seat Inspection (CSI) processes, and makes continuous improvements to both. Participates in dress cover workshops, and is responsible for dress cover reference sample approval for HoV programs. Prepares necessary documentation (datasheets, photographs) for approval of dress covers for HoV programs. Participates in Preliminary Design Reviews (PDR) and Critical Design Reviews (CDR) for HoV programs, and implements changes as necessary for quality inspection plans, per OEM and customer requirements for serial production of seats. Responsible to identify quality requirements within the customer program and resolve non-compliances. Responsible for driving APQP (Advanced Product Quality Planning) on HoV programs (development and production hand-over phases). DFMEA / PFMEAs alignment for HoV programs, until hand-off to process quality engineers. Measurement System Analysis, Statistical Process Control. Be able to use considerable judgement and discretion in performing your duties.

Requirements

Requires a bachelor’s degree in an engineering discipline.
Must have 3-5 years of related experience.
Prior experience managing/supervising teams.
Must have a working knowledge of Quality Management System requirements.
Knowledge of FAA and Aerospace OEM requirements is required.
Working knowledge on risk management tools.
Should have a background in product and process control methods.
Should have a working knowledge of statistical process control.
Must have a strong understanding continuous improvement methodologies and tools.
Must be familiar with manufacturing and production processes.
Project Management experience desired.
Must be able to read engineering drawings and Bill of Materials (BoM), complete basic statistical computations, write detailed reports.
Familiarity with products, its composition and the methods of production as well as an in-depth knowledge of quality guidelines, including customer requirements and regulatory requirements and procedures.
Ability to read and write English.
Ability to travel internationally.
Be able to work independently as well as be a team player.
Excellent interpersonal skills.

Nice To Haves

Experience in the automotive industry preferred.

Responsibilities

Responsible for timely completion of program launch deliverables.
Plans and supervises daily activities of quality project engineers, and measurement technicians to ensure adherence to established department, organization, and customer specification parameters.
Ensure customer requirements are understood and communicated to the departments.
Works with cross-functional teams (department and site) to address customers concerns from containment through the implementation of corrective/preventive actions.
Review existing data from past programs’ customer reviews, and provide feedback to the program team for improvement and risk mitigation for HoV programs.
Be the focal for Quality aspects (receiving inspection/FAI parts, supplier approval, FAI/CSI, test conformity, hand-over to process quality engineers) for assigned HoV programs.
Review and approve Design Change Proposals for seat programs, conforming to RECARO Quality System.
Review and approve effectivity lists for HoV programs.
Conduct daily shop floor meetings with the quality projects team, to oversee progress, and address deviations, and plan risk mitigation on on-going projects.
Work load planning and resource allocation for quality projects engineers, and measurement team.
Responsible for all personnel issues and performance evaluations of direct reports, including performance management, identifying training needs, capacity building and succession planning.
Develops and maintains quality statistics, charts defects and non-conformities utilizing computer system.
Maintains all relevant documentation.
Perform internal audit of the FAI/CSI process, and continually improve the processes.
Coordinate preparation and approval of commitment letters for deviations related to customer requirements on assigned HoV programs.
Prepare Quality Inspection Dossiers, for deviations from RECARO standards, and/or per customer requirements for HoV programs.
Establishes quality control plans for customer programs and ensures final product meets the required control plans.
Records and resolves deviations.
Acts as a liaison between customer program activities to final/ source inspectors to ensure final product meets the quality requirements of customer, regulatory authorities, OEM and internal specifications.
Analyze and assist in driving the DPU (Defects per Unit) reduction along with production team.
Liaise with OEM (Airbus and Boeing) inspection to reduce factory defects found at OEM facility.
Performs Quality inspections in a manner that ensures all quality and production standards are met and the final product meets RECARO engineering specifications, customer, and regulatory requirements (FAA, EASA, LBA, and other CAA) and OEM (Airbus and Boeing) specifications.
Assists and offers solutions for the successful resolution of quality issues.
Suggests new and improved methods for continuous improvement of the quality management system.
Maintains quality statistics, charts defects and nonconformities utilizing computer system.
Maintains all relevant documentation.
Is a Material Review Board (MRB) member, calls MRB Meeting and is part of the decision making process.
Prepares periodic reports pertaining to quality issues and their resolution from First Article Inspection (FAI) and Customer Seat Inspection (CSI).
As needed, calls MRB Meeting and is part of the decision making process.
Prepares reports pertaining to quality issues and their resolution.
Initiate quality documentation as required concerning issues of assembly and/or materials.
Coordinates closely with other RECARO sites to ensure consistency with practices, procedures and specifications.
Support Lean and 5S initiatives.
Participate actively in continuous improvement program and corrective action projects, contributing by leading specific improvement activities.
Perform root cause analysis of defects data and drive improvements.
Assists and implements solutions for the successful resolution of quality issues.
Suggests new and improved methods for continuous improvement of the quality management system.
Maintains complete knowledge of the Quality Management Manual and relevant procedures and follows all guidelines as defined by ISO9001/AS9100, Airbus and Boeing requirements, customer requirements, FAA and other regulatory authorities.
Perform First Article Inspection (Inspection & Measurement) on seats and prepare documentation in accordance with AS9102/ISO-9102.
Create MRBs to document non-conformities observed during final inspection, and first article inspection of the seat assembly and implements solutions.
Perform conformity inspection on test articles (seats and flammability test coupons).
Perform periodic review of the internal seat First Article Inspection (FAI) and Customer Seat Inspection (CSI) processes, and make continuous improvements to both.
Participate in dress cover workshops, and responsible for dress cover reference sample approval for HoV programs.
Prepare necessary documentation (datasheets, photographs) for approval of dress covers for HoV programs.
Participate in Preliminary Design Reviews (PDR) and Critical Design Reviews (CDR) for HoV programs, and implement changes as necessary for quality inspection plans, per OEM and customer requirements for serial production of seats.
Responsible to identify quality requirements within the customer program and resolve non-compliances.
Responsible for driving APQP (Advanced Product Quality Planning) on HoV programs (development and production hand-over phases).
DFMEA / PFMEAs alignment for HoV programs, until hand-off to process quality engineers.
Measurement System Analysis.
Statistical Process Control.