Quality Engineer (Lean Manufacturing & Kaizen)

Role: Quality Engineer (Lean Manufacturing & Kaizen)

Location: Houston, TX

Responsibilities

Lead and implement Kaizen initiatives across manufacturing processes to improve quality, productivity, safety, and cost.

Drive Lean Manufacturing practices including 5S, Value Stream Mapping (VSM), Poka-Yoke, SMED, Visual Management, and waste elimination.

Facilitate continuous improvement projects using PDCA, DMAIC, and Root Cause Analysis methodologies.

Conduct Root Cause Analysis using 8D, 5 Why, Fishbone Diagram, and implement corrective and preventive actions.

Develop and maintain Control Plans, PFMEA, Process Flow Diagrams, SOPs, and inspection standards.

Monitor process capability (Cp/Cpk), SPC, MSA, and identify opportunities for process improvement.

Coordinate with Production, Manufacturing Engineering, Design, Supply Chain, and Customer Quality teams to resolve quality issues.

Conducting internal audits & GEMBA Audits and preparing reports.

Lead internal quality audits and support customer and supplier audits.

Analyze quality metrics and implement initiatives to reduce defects, scrap, rework, and customer complaints.

Train and mentor production teams on Lean Manufacturing and Kaizen principles.

Ensure compliance with applicable quality management system requirements.

Required Skills

Strong expertise in Lean Manufacturing and Kaizen implementation.

Hands-on experience with 5S, VSM, SMED, Poka-Yoke, TPM, and continuous improvement methodologies.

Proficiency in APQP, PPAP, PFMEA, Control Plan, SPC, MSA, and 8D.

Strong problem-solving skills using 5 Why, Fishbone, Pareto Analysis, and statistical tools.

Ability to interpret engineering drawings and GD&T.

Excellent leadership, communication, and cross-functional collaboration skills.

Preferred Qualifications

Bachelor's degree in mechanical engineering.

Lean Six Sigma Green Belt or Black Belt certification is preferred.

8 to 12 Years of experience in industrial manufacturing.