Sr. Quality Engineer

Kapco Metal Stamping•Grafton, WI

7d•Onsite

About The Position

Kapco is looking for a Senior Quality Engineer to join our Grafton, WI team. The Senior Quality Engineer is responsible for developing and implementing quality systems, resolving complex quality issues, leading problem-solving initiatives, and driving continuous improvement efforts. This position requires a deep understanding of our customers’ quality standards, requirements, and manufacturing processes.

Requirements

5 years of experience in quality engineering and related disciplines including implementing and applying quality tools (APQP, FMEA, Control Plans, MSA, PPAP, SPC, GD&T) and problem-solving techniques (8D, 5-Why, etc.) in a manufacturing environment.
Bachelor’s degree in engineering or a related field, Industrial or Mechanical Engineering preferred.
Minimum (5-7) years in an APQP role.
Auditor experience (ISO 9000 and TS 16949)
Willing to travel (Domestic/International) up to 20%

Nice To Haves

ASQ CQE or CQA desirable
Structured problem-solving experience (Six Sigma Green Belt or Shainin Red “X” Journeyman) desired.

Responsibilities

Serve as the primary point of contact for assigned customers regarding quality concerns, audits, and performance reviews. Ensure customer satisfaction by addressing concerns and ensuring timely resolution of quality issues.
Work closely with cross-functional teams, including Operations, Engineering, and Supply Chain to resolve quality issues and implement quality improvements.
Monitor supplier portal in the system for customer quality issues and performance (coordinate responses with Quality Manger & functional Operations team members.
Develop, implement, and maintain quality assurance processes, launch plans, test plans, and inspection procedures to ensure product quality and compliance with standards.
Manage CAR analysis, lead cross-functional teams using problem solving methodologies to address internal and customer quality issues. Create corrective action plans to address process failures and prevent recurrence. Provide structured problem-solving support-reactive (field failure or testing) and preventive (mitigate NPD risk).
Develop and maintain process control plans, PFMEA’s and control charts. Drive process improvements to enhance product quality and manufacturing efficiency.
Support and coach team members on quality standards and expectations. Coach in the use of fundamental APQP tools (PPAP, DFMEA, PFMEA, Process Validation Plans and Production Control Plans).
Support new product introductions by ensuring quality standards are met during pre-production and production phases. Participate in APQP activities and validate PPAP submissions.
Assist in the development of dimensional control strategies with customers.
Assist in the design and procurement of gages and instruments with customers.
Conduct and direct MSA activities on new gauges and precision equipment.
Monitor, analyze and improve daily, weekly, and monthly quality metrics such as PPM, Cost of Quality, and Corrective Action timing and response. Report on quality performance and lead initiatives to achieve quality objectives.
Document and distribute lessons learned to the organization.