The Quality Assurance (QA) Manager ensures the products manufactured by Suncast Corporation fit the purpose and meet the expectations of the customer and comply with applicable laws and regulations. The QA Manager develops and coordinates all activities and programs necessary to meet and maintain quality standards and reliability of manufactured products. These goals are achieved through documentation of the product’s test results and providing suggestions to attain the best quality product possible. The QA Manager establishes, manages, and implements product quality programs and supervises a staff of more than twenty QA inspectors and technicians.
Essential Duties and Responsibilities:
The following duties are considered essential to this position. Other responsibilities may be assigned.
- Review non‑conformance data and evaluate non‑conformance records. Determine if a root cause analysis is needed for the rejection.
- Determine recurring trends.
- Identify who is assigned root cause / corrective action duties.
- Coordinate the implementation of corrective actions.
- Report on product inspection yields. Distribute to production and upper management. Compile monthly reports to show trends and summarize action that has been taken to improve quality.
- Oversee the inspection function. This includes resource allocation, training and supervising inspectors, planning the inspection process, and hiring and promoting inspectors. Inspection areas include all production departments, receiving, and the warehouse.
- Ensure that drawings on engineering standard sheets are clear and accurate.
- Evaluate new production methods for new or existing products.
- Report on areas that may result in defects or customer dissatisfaction and propose solutions.
- Ensure that all products have up to date inspection sheets. Ensure that inspectors are using these sheets and performing all required tests on schedule.
- Develop an inspection plan for all products. This will outline inspection method, lot size, sample size and defect action. Use statistical methods. Ensure Directed Audit program has current instructions and settings.
- Attend all new product pre-pilot, pilot runs and first production runs.
- Ensure each shift has adequate support the first-time production runs on that shift. Ensure that production support such as assistant supervisors, technicians, and group leaders are aware of quality issues as they arise.
- Ensure that quality concerns are understood and addressed. Suggest production, mold, and packaging changes to improve customer satisfaction.
- Ensure that all required fixtures and equipment will be available for production and inspection.
- Lead meetings to provide information concerning quality responsibilities and findings. These include shift change meetings held three times each day during QA overlap periods.
- Review daily non-conformances and report findings with the department manager.
- Monitor all inventories on hold. Disposition product in a timely manner to minimize on hold inventory.
- Plan and coordinate warehouse quality audits. Direct warehouse auditor. Review findings and issue disposition.
- Conduct “ICAR” meetings with other departments to apply corrective action to historic quality errors.
- Read trade journals and technical publications regularly to stay informed of technological changes.
- The employee should suggest trade shows and seminars that will inform him or her of new techniques and materials.
- Support and comply with all Suncast safety policies, quality standards, and housekeeping methods at all times. Suncast policies have been developed to ensure compliance with employee law.
- Explain company policies to workers and enforce safety regulations.
- Initiate or suggest plans to motivate workers to achieve work goals.
- Assist workers in resolving work related problems.
- Confer with the director on staffing, hiring, and disciplining employees.
- Maintain employee time and production records.
- Prepare required annual personnel performance reviews in a timely basis.
Supervisory Responsibilities:
This position has supervisory responsibility for the following positions:
- Quality Leader
- QA Inspectors (three shifts)
- QA Technicians
- Lead QA Inspectors
- Q. A. Engineers
- Others as assigned
Qualifications:
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required.
- Bachelor’s degree in Manufacturing Technology, Industrial Engineering, Quality Management, Business or a related discipline required. Significant relevant experience in role in lieu of qualifications is acceptable.
- Five to ten years’ experience in plastics manufacturing quality assurance or product testing required.
- One to three of the years of experience should include employee supervision.
- Six Sigma Green Belt or Black belt certified preferred.
- ASQ Certified Quality Engineer a plus
- Certified Lead Auditor – ISO 9000 a plus.
- Analytical and critical thinking skills
- Continuous improvement mindset
- Technically and commercially savvy
- Ability to work in a diverse and dynamic environment
- Good Organizational, Planning and Prioritizing skills
- Good communication and interpersonal skills
- Ability to present data effectively
- Ability to multi-task and change responsibilities as needed
- Excellent Communication and Interpersonal skills; both written and verbal
- Work independently with minimal supervision
- Strong knowledge of relevant software, quality assurance methods, tools and quality manufacturing processes (TQM, APQP, PPAP, DVP&R, FMEA, Statistical analysis and control, Inspection methodology, etc.)
- Application knowledge of ISO9001 and/or TS16949
- Understanding of engineering drawings and manufacturing processes
- Problem-solving skills and Corrective Action.
- Proven track record for developing shop floor relations ships is essential
- Measurement and/or Inspection experience (MSA, Gage R&R, Calibration)
- History of identifying and resolving quality and delivery issues, including part containment, risk assessment, utilization of formal quality tools and processes
- Capability to inspect, verify parts and processes (1st piece, source inspection, material certs, FAI)
- Auditing / Assessing to Customer requirements and Industry specifications (like AS9100, AS9110, ISO9001)
- Use of Lean methodologies and Six Sigma tools
- Quality metric and KPI establishment, tracking, control charts, improvement. Ability to perform data analysis.
- Read, analyze, and interpret general business periodicals, professional journals, technical procedures, or government regulations.
- Respond effectively to questions from managers, engineers, coworkers, and subordinates.
- speak clearly and professionally on the telephone to customers
- Write reports and procedures
- Present information clearly to managers, engineers, customers, buyers, coworkers, and employees who report to this person.
- Communicate with the majority of the hourly workforce. Bi-lingual in English and Spanish a plus.
- Ability to apply advanced mathematical concepts such as exponents, logarithms, quadratic equations, and permutations and mathematical operations to tasks such as frequency distribution, determination of test reliability and validity, analysis of variance, correlation techniques, sampling theory, and factor analysis.
- Ability to define problems, collect data, establish facts, draw valid conclusions. Interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables.
- While performing this job, the employee will use a computer extensively. Expert spreadsheet skills for data analysis required. Must be able to construct complex formulas, draw graphs, and link files. Advanced word processor skills for report writing. Advanced database skills. Ability to design a new database with data analysis features. Ability to perform research on the Internet. Proficient with Microsoft Office. AS400 experience is a plus.
Physical Demands:
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
While performing this job, the employee will be required to sit, use a computer with a keyboard and mouse, effectively communicate with others, and use active listening skills. On occasion he or she will be required to walk within office and manufacturing areas, up and down stairs, and carry up to 50 pounds. Vision requirements include ability for close vision so printed reports and computer screens can be read, distance vision, and the ability to focus. Color acuity is a plus.
Work Environment:
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
While performing these duties, the employee will spend part of his or her time in an office environment, and part of the time in a manufacturing environment. Typically, offices are climate controlled and have a moderate noise level for an office. Manufacturing areas are subject to seasonal variations in temperature and humidity. Noise level is generally moderate for manufacturing. PPE Safety equipment is required when in internal manufacturing areas. This is a full-time position. Because this position has responsibility for around-the-clock activity, the employee may be required to be on-call during evenings and weekends.