Sr Quality Engineer

Position: Senior Quality Engineer

Location: Santa Ana, CA

Department: Quality

Reports To: Quality Manager

Classification: Exempt

Shift: Full-Time

Compensation: $83,336 $160,862 annually

Now Hiring: Senior Quality Engineer

FLAG's mission is to show our contractors & clients the best this industry can offer by upholding our principles of leadership, service, and exceptionalism.

A confidential manufacturing company is seeking an experienced Senior Quality Engineer to lead complex quality initiatives within a sheet metal fabrication environment. This position will have significant responsibility for PPAP, APQP, FMEA, Gage R&R, quality systems, corrective actions, supplier quality, and continuous improvement.

1. Job Summary

The Senior Quality Engineer is responsible for ensuring products and manufacturing processes meet customer, regulatory, and internal quality requirements. This position leads quality activities related to PPAP, new product introduction, process validation, nonconforming material, root cause analysis, corrective action, supplier quality, and customer concerns.

Operating with a high degree of independence, the Senior Quality Engineer will lead complex projects, analyze quality performance, implement sustainable improvements, and provide technical guidance to other team members. The role works closely with Manufacturing, Engineering, suppliers, customers, and management to reduce variation, prevent defects, and improve overall product quality.

2. Essential Duties & Responsibilities

Advanced Quality & PPAP

• Manage the Production Part Approval Process (PPAP), including first-off sample approvals and supporting documentation.
• Lead Advanced Product Quality Planning (APQP) activities for new and existing products.
• Develop and maintain Control Plans, Process FMEAs, and related quality documentation.
• Perform and evaluate Gage Repeatability and Reproducibility (Gage R&R) studies .
• Apply Measurement System Analysis (MSA) methodologies to validate measurement systems.
• Support new product introductions to ensure robust manufacturing and inspection processes.
• Develop product testing procedures and quality requirements.

Root Cause & Corrective Action

• Lead investigations involving internal, supplier, customer, and warranty quality issues.
• Perform root cause analysis and implement permanent corrective actions.
• Lead structured problem-solving activities to prevent recurrence of quality issues.
• Work with internal and external stakeholders to resolve quality concerns quickly and effectively.
• Stop production when unacceptable products or processes present a quality or safety risk.

Quality Systems & Auditing

• Support compliance with AS9100D and ISO 9001 Quality Management System requirements.
• Lead product, process, supplier, and quality system audits.
• Ensure Control Plans and quality documentation are effectively implemented and maintained.
• Support applicable ISO 14001 and health, safety, and environmental requirements.
• Train employees on quality systems, procedures, and quality awareness.

Quality Metrics & Supplier Quality

• Monitor and report KPIs including scrap, rework, customer PPM, supplier PPM, and cost of quality.
• Manage supplier quality performance and associated KPIs.
• Coordinate supplier corrective actions, problem resolution, cost recovery, and warranty issues.
• Analyze quality trends and implement improvements based on performance data.
• Prepare technical reports and present quality performance to management and customers.

Continuous Improvement

• Lead continuous improvement and process optimization initiatives.
• Apply Lean Manufacturing, Six Sigma, Poka-Yoke, FMEA, and MSA methodologies to reduce defects and process variation.
• Identify opportunities to improve quality, reduce waste, and lower manufacturing costs.
• Conduct benchmarking studies to identify manufacturing and quality best practices.
• Lead complex quality projects from planning through implementation and completion.

Technical Leadership & Collaboration

• Provide technical guidance and mentorship to Quality team members and other employees.
• Train team members on quality tools, processes, and problem-solving methodologies.
• Lead cross-functional quality initiatives involving Manufacturing, Engineering, suppliers, and customers.
• Communicate directly with customers and suppliers regarding technical quality requirements and corrective actions.
• Independently establish technical approaches and priorities for assigned projects.

3. Qualifications

Required

• Bachelor's degree in Mechanical Engineering, Engineering Technology, or a related technical discipline .
• Minimum of 8 years of manufacturing and/or quality engineering experience .
• Sheet metal fabrication experience.
• Advanced knowledge of APQP, PPAP, FMEA, Control Plans, and MSA .
• Hands-on experience performing Gage R&R studies .
• Strong knowledge of AS9100D and ISO 9001 quality systems.
• Experience leading root cause analysis and corrective action investigations.
• Experience conducting and leading quality audits.
• Ability to read and interpret engineering drawings and manufacturing specifications.
• Strong understanding of manufacturing processes and quality measurement techniques.

Preferred

• Aerospace or precision manufacturing experience.
• Lean Manufacturing and Six Sigma experience.
• Supplier Quality Engineering experience.
• Experience with Poka-Yoke/error-proofing methodologies.
• Knowledge of ISO 14001.
• Experience with Global Shop Solutions ERP.
• Experience leading new product introduction and cross-functional APQP activities.
• Experience mentoring or training Quality Engineers and manufacturing personnel.

4. Physical Requirements

• Ability to work in both office and manufacturing environments.
• Frequent computer use and review of engineering drawings, specifications, and quality documentation.
• Regular standing and walking throughout the manufacturing facility.
• Ability to perform or support shop-floor product and process inspections.
• Occasional bending and reaching as required to evaluate manufacturing processes and products.

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