Quality Engineer (Cut & Sew) Marine Components

Description

Position Summary

The Quality Engineer is responsible for supporting all quality functions and supervision of Process Auditor. This role partners closely with production engineering and supply chain teams to drive continuous improvement resolve quality issues and implement robust quality systems that support world-class manufacturing role will be responsible for the Cutting Embroidery Quilting Sewing and final assembly of Seat and Back Cover Assemblies for marine applications. The role is responsible for the development of all PPAP Packages and communications with all customers. This role leads efforts to reduce Cost of Poor Quality including rework quality issues and defects in the process. This person is responsible for communicating with all relevant stakeholders on activities including critical quality issues project status root cause analysis and corrective actions. The ideal candidate is direct data-driven and enthusiastic about delivering positive/exceptional customer experience through flawless product quality.

Key Responsibilities

Product & Process Quality

• Lead plant-level quality activities to ensure products meet specifications and customer expectations. Manage all Process Auditor(s).
• Analyze and facilitate efforts to reduce internal Scrap and Rework.
• Analyze and facilitate efforts to reduce process defects and non-conformances at all stages of the process.
• Monitor in-process and final product quality metrics (FPY DPU COPQ scrap rework warranty trends)
• Develop and maintain control plans work instructions inspection standards and quality documentation.
• Perform layered process audits and product audits to verify compliance.
• Provide primary support in the creation/completion of the Monthly Quality Updates
• Lead improvement projects based on internal quality metrics/data warranty data and customer feedback to reduce and eliminate repeat issues while improving overall quality of product(s)
• Develop criteria for acceptance documents FMEA control plans Product/Process Check Sheets Work Instructions as needed to communicate requirements to production and inspection teams.

Problem Solving & Root Cause Analysis

• Lead root cause investigations using structured methodologies (8D A3 5 Whys Fishbone)
• Implement and validate corrective and preventive actions (CAPA methodology)
• Support containment actions to protect customers and production flow.
• Analyze internal defects and field/warranty data to identify systemic issues.

Continuous Improvement

• Support/Drive Lean or structured methodologies (Six Sigma) to improve product quality and reduce variation.
• Identify and eliminate waste through process optimization and mistake-proofing (poka-yoke)
• Support Kaizen events and cross-functional improvement projects.

Cross-Functional Collaboration

• Work closely with Manufacturing Engineering Design Engineering Supplier Quality Supply Chain and Production teams to resolve quality issues.
• Participate in new product introduction (NPI) to ensure designs are manufacturable and meet quality standards.
• Provide feedback on design improvements based on plant and field data.

Supplier Quality Support

• Collaborate with Supplier Quality and Procurement to address incoming material issues.
• Support and manage selected suppliers. Develop with the suppliers corrective actions and qualification activities as needed.
• Approve Supplier PPAPs.
• Develop Scorecards for certain Commodities when required.

Customer & Warranty Focus

• Review warranty claims and customer feedback to identify trends.
• Support field issue resolution and corrective action implementation.
• Ensure lessons learned are communicated and incorporated into processes.
• Interface with Customers related to quality issues and present data and corrective actions.

Compliance & Standards

• Maintain compliance with company quality systems and applicable standards.
• Support internal and external audits.
• Ensure adherence to safety and environmental regulations.
• Provide support or lead efforts to all assigned quality team members to ensure training development and support as needed in the completion of their duties.

Miscellaneous Responsibilities

• Teamwork: Balances team and individual responsibilities; Exhibits objectivity and openness to others views; Gives and welcomes feedback; Contributes to building a positive team spirit; Puts success of team above own interests; Supports everyones efforts to succeed.
• Learn how to measure parts as needed using CMM/Scanner or other measuring systems.
• Ensure product/process tests and procedures are properly understood conducted and evaluated and that product/process modifications are investigated if necessary.
• Develop tools/fixtures to aid in the process and improve efficiency.
• May be customer facing requiring issue investigation CAR completion internal solution validation proper communication and documentation control.
• Maintain spending in support of departmental budget goals.
• Other duties as assigned.

#MalibuBoats

Qualifications

• Bachelors degree in engineering (Mechanical Industrial Manufacturing or related field) or Business (with strong technical focus)
• E quivalent >8 years related experience. Could include formal training/certifications in quality disciplines and 5 years related experience.
• 3 years of experience in a manufacturing (shop floor) quality role
• Strong knowledge of quality tools (SPC FMEA Control Plans MSA)
• Experience with root cause analysis and corrective action methodologies
• Ability to interpret engineering drawings and specifications.
• Strong analytical and critical thinking skills
• Demonstrated fit in team and at site well respected and collaborative.

Preferred

• Experience in marine automotive RV or similar assembly manufacturing environments
• Lean Six Sigma certification (Green Belt or higher)
• Familiarity with cut and sewing manufacturing processes
• Experience with ERP/MES systems and quality data analysis tools
• Strong corrective action and troubleshooting background required.
• Strong PPAP Gage R&R 8Ds & 5Why Analysis
• Experience managing projects or leading a team required.
• Boat manufacturing experience is a plus.
• Six Sigma training is a plus.
• Ability to travel (<25%) with little notice.

Key Competencies

• Direct shop-floor oriented mindset
• High diligence and commitment to excellence
• Effective communication and people skills.
• Ability to influence cross-functional teams and build dynamic relationships.
• Ownership mentality and accountability
• Continuous improvement mindset
• High attention to details
• High attention to issue closure and metrics

Other Preferred Qualifications:

Conditions

• Primarily based in a manufacturing plant environment. Experience with Wiring Harness Cutting Crimping Terminal Installation Welding Continuity Checks 3-5 Axis machining Tube Bending etc
• Frequent interaction with production floor and firsthand problem solving.
• Occasional travel to customers suppliers or other Malibu Boats facilities

What Success Looks Like in 3-12 Months

• Measurable reduction in defects rework and warranty and impact to COPQ
• Stable predictable processes with strong process controls
• Documented sustainable solutions that improve quality metrics.
• Faster more effective problem solving with low recurrence.
• Improved plant quality culture (operator ownership)
• Strong influence on product design feedback loop
• Recognized as a go-to leader on the shop floor.

Why Malibu Boats

• Industry leader in performance boats and innovation
• Strong culture of quality craftsmanship and customer passion
• Opportunity to directly impact product excellence and customer satisfaction.

12-Month Targets & Metrics

1. Product Quality Performance

• First Pass Yield (FPY):
  • Target: 9598% (depending on baseline)
  • Improvement: 35 percentage points vs. start of year
• Internal Defect Rate (PPM or DPU):
  • Target: 3050% reduction YoY
  • Focus on top 5 recurring defect categories.
• Scrap & Rework Cost:
  • Target: 2030% reduction
  • Measured as COPQ - % of Revenue and cost per boat.

2. Warranty & Customer Quality

• Warranty Claims Rate:
  • Target: 25% reduction YoY
• Top Warranty Drivers:
  • Reduce top 3 failure modes by 40%.
• Customer Satisfaction (Quality-related):
  • Improve quality-related NPS/CSI inputs by measurable margin.

3. Problem Solving Effectiveness

• Corrective Action Closure Time:
  • Target: < 30 days average (for standard issues)
  • Containment within 2448 hours
• Recurrence Rate:
  • Target: < 10% repeat issues after closure
• 8D / A3 Quality Score:
  • 90% on internal quality audits of problem-solving rigor

4. Process Control & Stability

• PFMEA/Control Plan drive into Top 3 substantial risk processes
• Control Plan Adherence:
  • 95% audit compliance
• Layered Process Audit (LPA) Completion:
  • 98% on time completion
  • Closure of findings within 14 days

8. Culture & Engagement

• Quality Training & Awareness:
  • Train / coach operators on critical quality standards
  • Conduct monthly quality stand-downs or refreshers.
• Employee Quality Suggestions:
  • Adopt ideas from production teams.
• Escapes (Customer or line-stop events):
  • Zero major escapes
  • 50% reduction in minor escapes

Required Experience:

IC