Senior Quality Assurance Engineer

Senior Quality Engineer

Department: Quality Assurance

Designation: Senior Quality Engineer

Reporting To: Quality Manager / Assistant Quality Manager

Industry: Automotive Manufacturing – Sheet Metal Stamping, Press Shop, and Plastic Injection Molding

1. Job PurposeTo ensure product and process quality across Press Shop, Sheet Metal Stamping, and Plastic Injection Molding operations by implementing quality standards, monitoring process performance, resolving quality issues, and ensuring compliance with customer-specific requirements and IATF 16949 standards.

2. Key Responsibilities

A. Press Shop & Sheet Metal Stamping Quality

• Monitor quality of sheet metal stamping, piercing, blanking, bending, forming, and related assembly processes.
• Ensure compliance with drawings, dimensional specifications, and approved inspection standards.
• Monitor die condition, process parameters, first-off approval, and in-process inspection.
• Analyze stamping defects such as burrs, cracks, deformation, hole shift, dimensional variation, and forming defects.
• Coordinate with Production and Tool Room teams for die-related issues and process improvements.

B. Plastic Injection Molding Quality

• Monitor injection molding processes and ensure adherence to approved process parameters.
• Verify critical parameters such as temperature, injection pressure, holding pressure, cooling time, and cycle time.
• Analyze molding defects such as sink marks, silver marks, short shots, flash, warpage, burn marks, and cracks.
• Coordinate mold trials, mold maintenance, and process parameter validation.
• Ensure proper material handling, drying, mixing, traceability, and control of regrind as per approved requirements.

C. Quality Management System

• Implement and maintain quality system requirements as per IATF 16949 and customer-specific requirements.
• Prepare, review, and update PFMEA, Control Plans, Process Flow Diagrams, inspection standards, and work instructions.
• Conduct internal process audits, product audits, and layered process audits as applicable.
• Ensure compliance with document control, calibration, traceability, and nonconforming product control requirements.
• Support customer audits, certification audits, and supplier quality activities as assigned.

D. Customer Complaints & Problem Solving

• Handle internal and customer quality complaints and coordinate containment activities.
• Prepare 8D reports and conduct root cause analysis using 5 Why Analysis and Fishbone Diagrams.
• Implement corrective and preventive actions and verify their effectiveness.
• Monitor rejection, rework, scrap, and customer PPM performance.
• Ensure timely submission of corrective action reports and supporting evidence.

E. Core Quality Tools

• Apply APQP and PPAP requirements for new product development and process changes.
• Conduct or coordinate MSA, SPC, and process capability studies (Cp/Cpk).
• Use Pareto Analysis, trend analysis, and statistical methods to identify major quality losses.
• Ensure implementation of Poka-Yoke, error-proofing, and preventive quality controls.
• Support FMEA reviews and ensure identified risks are addressed through appropriate controls.

F. Continuous Improvement

• Identify opportunities to reduce rejection, rework, scrap, and process variation.
• Monitor quality KPIs and prepare periodic quality performance reports.
• Coordinate with Production, Maintenance, Tool Room, PPC, and other departments to resolve recurring quality issues.
• Drive corrective actions and continuous improvement activities to improve process capability and customer satisfaction.
• 3. Technical KnowledgePress Shop operations, sheet metal stamping, tooling, and die maintenance.
• Plastic Injection Molding processes, mold maintenance, and process parameter control.
• Automotive drawings, GD&T, dimensional inspection, and measuring instruments.
• IATF 16949, ISO 9001, customer-specific requirements, and automotive quality documentation.
• APQP, PPAP, PFMEA, Control Plan, MSA, SPC, Cp/Cpk, and 8D methodology.
• Root Cause Analysis, 5 Why Analysis, Fishbone Diagram, Pareto Analysis, and Poka-Yoke.
• Basic understanding of statistical analysis and Minitab, where applicable.
• 4. Hands-on ExperienceConducting first-piece, patrol, in-process, and final inspections.
• Performing defect analysis and troubleshooting stamping and molding quality issues.
• Preparing and implementing 8D reports, corrective actions, and effectiveness verification.
• Preparing and updating PFMEA, Control Plans, inspection reports, and PPAP documentation.
• Conducting MSA, SPC, and Cp/Cpk studies and interpreting the results.
• Performing process audits and monitoring compliance with approved process standards.
• Handling customer complaints, rejection reduction projects, and continuous improvement activities.
• 5. Education & ExperienceEducation: Diploma or Bachelor's degree in Mechanical, Production, or related engineering discipline preferred.
• Experience: 5–8 years of relevant experience in automotive manufacturing quality, including Press Shop and/or Plastic Injection Molding.
• Preferred Industry Experience: Automotive OEM or Tier-1 supplier environment.
• Additional Requirement: Practical knowledge of IATF 16949 and automotive core quality tools.
• 6. Key Performance Indicators (KPIs)Customer PPM and customer complaint closure.
• Internal rejection, rework, and scrap reduction.
• First-pass yield and process quality performance.
• Timely closure and effectiveness of corrective actions.
• Audit nonconformity closure and compliance.
• Completion of quality improvement projects.
• Process capability and adherence to approved control plans.
• 7. Skills & CompetenciesAnalytical thinking and problem-solving.
• Effective communication and cross-functional coordination.
• Documentation and report preparation.
• Decision-making based on data and facts.
• Ability to coordinate with Production, Maintenance, Tool Room, and customer representatives.