Lead Quality Assurance Engineer

How will you make an impact? The Quality Assurance NPI Engineer will support the launch and production readiness of a coolant plate machining facility. This role owns product and process quality activities from early customer requirement review through engineering evaluation, production validation, successful NPI launch, and structured handoff to sustaining quality engineering for mass production. This position is responsible for ensuring customer expectations, CTQs, drawings, specifications, datum structures, true position requirements, GD&T, inspection strategy, FMEA, control plans, procedures, and validation records are properly captured, documented, and executed throughout the NPI lifecycle. The role will work closely with Manufacturing, Engineering, Process Engineering, Metrology, Operations, Supplier Quality, and Customer Quality to ensure a controlled and successful product launch. Location: This role will be onsite and will work a day shift schedule Mon- Fri. What will you do? NPI Quality Ownership & Launch Readiness- Own the Quality Assurance execution of coolant plate NPI activities from customer requirement review through engineering evaluation, production validation, and launch readiness. Review customer requirements, drawings, CAD models, specifications, BOMs, CTQs, critical characteristics, datum schemes, true position requirements, GD&T callouts, and inspection expectations during the initial phases of NPI. Translate customer and engineering requirements into internal quality plans, inspection plans, control plans, work instructions, visual aids, quality gates, and acceptance criteria. Ensure all customer expectations and product-specific requirements are documented, communicated, and flowed into manufacturing, inspection, and validation processes. Lead or support NPI readiness reviews, risk reviews, quality gate reviews, first build reviews, pilot build reviews, and production validation reviews. Document engineering evaluation and production validation phases using PFMEA, control plans, inspection records, dimensional reports, MSA, Gage R&R, capability studies, nonconformance records, and lessons learned. Ensure procedures, inspection work instructions, visual standards, defect criteria, training material, and quality records are created before successful NPI launch. After successful NPI launch, coordinate the structured handoff of product knowledge, open risks, quality controls, inspection methods, lessons learned, and documentation to sustain quality engineers for mass production support. Coolant Plate Machining Quality- Support quality planning and execution for metal machining of coolant plates, including CNC machining, critical feature control, dimensional inspection, deburr, cleaning, leak‑related characteristics, and internal feature inspection where applicable. Identify and validate CTQs and special characteristics tied to fit, form, function, datum alignment, true position, sealing surfaces, internal channels, mounting features, and customer‑defined acceptance criteria. Partner with Manufacturing and Process Engineering to define process controls, inspection checkpoints, reaction plans, and defect prevention methods for coolant plate machining operations. Support process capability validation for critical dimensions and machining characteristics using Cp/Cpk, Pp/Ppk, SPC, trend reviews, and appropriate containment plans when capability is not yet mature. Support incoming quality criteria and supplier quality alignment for raw material, machining‑related inputs, critical components, and special processes associated with coolant plate manufacturing. CMM, Metrology & Dimensional Inspection- Support CMM inspection strategy, CMM program development, program validation, revision alignment, and inspection method readiness for coolant plate products. Create, modify, or support CMM programs using engineering drawings, CAD models, datum structures, true position requirements, GD&T, CTQs, and product‑specific inspection strategy. Ensure CMM programs, inspection plans, and dimensional reports are aligned to the released drawing/CAD revision and are controlled before use in engineering evaluation, production validation, or production release. Support CMM fixture development and validation, including part orientation, datum simulation, repeatability, accessibility, probe clearance, and traceability by fixture position, job number, serial number, or lot where applicable. Lead or support MSA, Gage R&R, repeatability studies, correlation studies, and measurement method validation for critical dimensions and CTQs. Ensure dimensional inspection results are clearly documented, traceable, reviewed, and linked to the applicable build phase, drawing revision, production lot, job number, or validation record. Visual, 3D & X‑Ray Inspection Readiness- Define and support visual inspection requirements for coolant plate machining defects, burrs, surface conditions, cosmetic requirements, dimensional anomalies, brazing‑related concerns, and other process‑related failure modes. Develop or support visual standards, defect libraries, acceptance criteria, inspection work instructions, and training material for inspectors and production teams. Support 3D inspection, optical measurement, or scanning methods where applicable to validate geometry, profile, flatness, feature location, and other critical characteristics. Support X‑Ray or CT inspection development for internal coolant plate features, blocked channels, voids, brazing quality, internal geometry, or customer‑defined failure modes where applicable. Partner with Engineering, Metrology, and equipment suppliers to define inspection capability, limitations, programming needs, GR&R approach, and validation requirements for 3D and X‑Ray inspection methods. Ensure inspection records, images, scans, CMM reports, X‑Ray/CT results, and supporting data are retained and traceable to the appropriate product, lot, job, and validation phase. PFMEA, Control Plan & Documentation- Lead or support development of PFMEA and control plans for coolant plate machining, inspection, cleaning, leak‑related verification, internal feature inspection, packaging, and other applicable process steps. Ensure the process flow, PFMEA, control plan, work instructions, inspection methods, and reaction plans are linked and aligned before NPI launch. Create and maintain NPI quality documentation, including procedures, work instructions, inspection plans, quality alerts, visual aids, defect criteria, training records, launch checklists, and lessons learned. Ensure customer requirements and regulatory/internal quality requirements are translated into internal procedures and inspection documentation. Support change control and document control discipline for drawings, CAD files, BOMs, inspection plans, procedures, control plans, CMM programs, and validation records. Quality Assurance, Problem Solving & Customer Support- Support ISO 9001 quality system execution, internal audits, customer audit readiness, process verification, and production readiness assessments for the coolant plate product line. Support structured containment, nonconformance documentation, MRB input, disposition follow‑up, corrective action, and effectiveness verification for NPI‑related quality issues. Lead or support 8D/A3 investigations for NPI defects, customer concerns, dimensional issues, inspection failures, or validation gaps. Track quality performance during NPI and ramp, including FPY, DPPM, escapes, scrap, rework, capability, inspection findings, and closure of launch risks. Communicate quality status, open risks, inspection readiness, validation results, and escalation items to the Site Quality Assurance Manager and cross‑functional leadership. How will you get here? Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Quality Engineering, or a related technical field; equivalent education and experience may be considered. 5–8 years of experience in Quality Engineering, Manufacturing Quality, NPI Quality, Product Quality, Metrology, or Manufacturing Engineering. Hands‑on experience with metal machining, CNC machining, precision‑machined components, coolant plates, cold plates, brazed assemblies, thermal management products, or similar high‑precision manufacturing processes. Strong knowledge of engineering drawings, CAD model interpretation, CTQs, datum structure, true position, GD&T, dimensional inspection, tolerance interpretation, and inspection planning. Experience supporting NPI, engineering evaluation builds, production validation, product transfer, pilot builds, production ramp, or new site launch activities. Experience with PFMEA, control plans, MSA/Gage R&R, FAI, PPAP/APQP concepts, process capability, SPC, nonconformance management, and corrective action. Experience with CMM inspection strategy, CMM program support, dimensional reports, measurement validation, and metrology documentation. Working knowledge of ISO 9001 or similar Quality Management System requirements. Strong communication skills with ability to work cross‑functionally with Manufacturing, Engineering, Operations, Supplier Quality, Customer Quality, and Metrology teams. Preferred Qualifications- Experience with ZEISS CMM equipment and CALYPSO programming strongly preferred. Experience with 3D scanning, optical measurement, CT/X‑Ray inspection, or advanced metrology systems. Experience with coolant plate or cold plate manufacturing, including machining, brazing, leak testing, cleaning, internal feature inspection, sealing surfaces, or thermal management products. Experience creating NPI quality documentation, including PFMEA, control plans, inspection work instructions, visual standards, defect libraries, production validation records, and launch handoff packages. Experience with supplier quality, incoming inspection criteria, customer‑facing quality communication, and APQP/PPAP‑style launch discipline. ASQ CQE, Six Sigma Green Belt, or similar certification preferred. Experience with MES, ERP, PLM/document control systems, Power BI, Tableau, or quality data dashboards preferred. Technical Skills- Coolant plate machining quality and NPI launch execution. CTQ identification and special characteristic management. GD&T interpretation, datum structure, and true position evaluation. CMM inspection strategy, programming support, and dimensional reporting. Blueprint, CAD model, BOM, and specification review. PFMEA, control plan, process flow, and quality gate development. Engineering evaluation and production validation documentation. MSA, Gage R&R, process capability, and SPC. Visual inspection standards and defect criteria. 3D inspection / scanning and X‑Ray / CT inspection support. Nonconformance management, 8D/A3, CAPA, and containment. ISO 9001 compliance, document control, and change control. Key Competencies- Strong technical judgment with a hands‑on manufacturing support mindset. Ability to translate customer requirements into practical quality controls. High attention to CTQs, datum strategy, GD&T, inspection method, and traceability details. Strong ownership of NPI launch readiness and product handoff discipline. Clear communication with operators, engineers, suppliers, customers, and leadership. Ability to work through ambiguity during new product and new site launch. Strong problem‑solving, escalation, and risk‑closure discipline. Quality‑first mindset focused on prevention, documentation, and sustainable mass‑production readiness. Success Measures- Customer requirements, CTQs, datum structures, true position requirements, GD&T, and inspection expectations are clearly captured before launch. Engineering evaluation and production validation phases are fully documented with FMEA, control plan, inspection records, validation results, and lessons learned. CMM/inspection methods are validated, controlled, and ready before pilot and production ramp. NPI quality risks are identified early, escalated appropriately, and driven to closure. Procedures, work instructions, visual standards, inspection plans, and training documents are released before launch. Successful NPI launch is followed by a clear handoff package to sustain quality engineering for mass production. FPY/yield improves, DPPM and escapes decrease, and CAPA effectiveness is verified during ramp. #J-18808-Ljbffr Plasticos Castella SA