Quality Assurance Specialist

  I.              General Summary:  To plan, develop, implement quality systems to ensure plant parts meet or exceed customer expectations.  Responsible for investigating, analyzing, containing, and correcting quality problems related to final customer products.                       This position may also perform audits and implement new strategies to improve the condition of plant quality. 

II.            Essential Job Functions:

A.      Facilitate and coordinate ECR (Engineering Change Request) and ECI (Engineering Change Information) activities for the Quality Department including:

a.        Collection of plant wide Design issues as defined by the QC Specialists/Assistant Managers – AM’s/Managers) allowing creation and entry of ECR submission into TB NA-IMS (Toyota-Boshoku North American Issue Management System).

b.       Collection and breakdown of ECI information (print(s), specification change(s), part(s) affected, program(s) affected, implementation timing, etc...) from the TBA PM (Program Management) and PC (Production Control) Team.

c.        Communication of the ECI information to the applicable QC Specialists/AM’s/Managers.

d.       Coordination, tracking, and submission of PPAP (Production Part Approval Process) and PCR (Process Change Request) submissions to Suppliers and Customers for all ECI’s and Launch activities per TB and customer quality standards, Supplier Quality Assurance Manual (SQAM), Quality Assurance Standards (QAS), etc…

                                                                           i.      The Coordination portion of this activity will require this position to assist the QC Customer and Supplier Specialists to investigate and finalize supporting documentation for these submissions.

                                                                         ii.      Coordinate each phase of the quality control/assurance activities of new and existing projects to ensure product quality, schedules, and time frames meet customer requirements.

                                                                       iii.      Collect information and research data related to quality standard requirements to comply with Customer requirements.

                                                                       iv.      Review material lists of conformance to company standard practices in regard to parts and materials used.

                                                                         v.      Analyze processes for improvements, failure modes, stability, and capability.

                                                                       vi.      Coordinate process change requests and Engineering Change Instruction (ECI) implementation related to quality assurance activities including preparing supporting documentation, change point tracking, communications, sample part reviews, and scheduling trial parts.

B.      Work with applicable QC Specialists to perform FSR (Feasibility Study Requests) analysis and forward results to TBA PM.

C.      Serve as liaison between plant and its Customers/Suppliers providing quality related technical assistance in the investigation, containment, and resolution of quality problems.

D.      Conduct quality audits including IATF16949 and Internal Process Audits, problem analysis, and providing design/redesign input.

E.       Support and assist with planning, development, and implementation of quality systems and activities to ensure parts meet or exceed plant and Customer expectations. 

F.       Support service part quality issues and warranty claims as necessary.

G.      Assist in updating/developing quality management system (e.g., IATF16949) based procedures, forms, and instructions.

H.      Complete miscellaneous reporting, administrative, and other quality related functions for the Quality Control department as require           

III.               Minimum Qualifications/Requirements:  

Education:

•         Bachelor’s degree in Business, Manufacturing, Engineering, or related field required; or an equivalent combination of education and experience.

•         Additional trade education and Quality certifications are preferred.

 

Experience:

•         Greater than four (4) years of relevant experience required.

•         Minimum of two (2) years of industrial inspection experience. 

•         Automotive experience preferred.

•         Quality Control program launch experience for new programs.

•         Experience creating PPAP and Manufacturing Quality Chart (MQC) documents.

•         Experience with manufacturing processes, tooling, quality control methods, and statistical process control (SPC).

•         Experience with Toyota launch systems and requirements preferred.

•         Welding experience for arc, spot, and projection welding is a plus.

•         Injection Plastics and Urethane process experience are a plus.

•         Previous exposure to a multicultural office environment preferred.

 

Personal/Technical Skills:

•         Working knowledge of quality audit techniques. 

•         Basic shop math ability required (i.e., addition, subtraction, multiplication, division).

•         Understanding of conceptual math (i.e., basic geometry, charts and graphs) required.

•         Understanding of elementary statistical concepts (i.e., standard deviation, variance, etc.).

•         General understanding and working knowledge of product design specifications functions and quality standards of finished product as well as parts/materials used.

•         Thorough understanding and working knowledge of automotive plants and processes, company products, trade terminology, quality management and control systems and techniques, manufacturing processes, tooling and equipment, and machine operation.

•         Ability to read, interpret, and understand engineering documents such as automotive drawings (component, assembly, and equipment), technical standards, design specifications, general tolerances, critical characteristics, Geometric Dimensioning and Tolerancing (GD&T), Engineering Change Instructions (ECI), Prototype Parts Requests (PPR), and color instructions.

•         General understanding of the Toyota Supplier Quality Assurance Manual (SQAM) and Toyota Production System (TPS) is preferred.

•         Good understanding of seat, welding, door, carpet, and headliner processes are a plus.

•         Good presentation skills.

•         Effective time management skills.

•         Ability to work in a team environment.

•         Strong organization and planning skills.

•         Excellent critical thinking skills required.

•         Good assertiveness and negotiation skills.

•         Ability to understand inspection standards.

•         Hands-on, self-starter with a strong work ethic.

•         Active listener with effective communication skills.

•         Ability to compile effective and concise visual reports.

•         Ability to perform responsibilities with minimal supervision.

•         Ability to work in a fast-paced, multicultural work environment.

•         Ability to maintain records and files and prepare recaps and reports.

•         Ability to maintain on call flexibility to control abnormal conditions.

•         Ability to be flexible in a constantly changing production environment.

•         Ability to communicate and work well with all levels of the organization.

•         Ability to create excellent working relationships with internal and external customers.

•         Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.

•         Ability to multitask, manage diversity, and facilitate effective problem solving and resolution.

 

Language Skills:

•         Strong verbal and written communication skills in English.

•         Japanese is a plus.

 

Computer/Software:

•         Solid working knowledge and experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Outlook, Internet, Newton, NEC, etc.).

•         AutoCAD experience is desirable.

IV.               Work Environment/Conditions:

Office:  Open Office Environment, moderate noise level.

Plant:  Standard automotive plant environment with moderate noise level.  PPE (Personal Protective Equipment) such as safety glasses, steel toe shoes, hearing protection, etc. may be required in engineering, manufacturing, or industrial areas.  Personal attire standards may apply.

Travel:  Must be willing to travel up to 10% of the time to TBA, Supplier, and Customer plants.  Travel with short notice often required.

V.                Physical Demands:  Ability to sit and work on a computer for extensive periods of time is required.  While performing the duties of this job, the team member is required to talk, see, and hear.  The team member must be capable of walking, sitting, and standing for extended periods of time.  May be occasionally required to lift up to 30 pounds. 

Disclaimer: This job description is intended to identify the general nature and level of work performed by team members within this classification, as well as certain essential job functions. It is not intended, and should not be interpreted, as a comprehensive inventory of all duties, responsibilities, and qualifications required of team members assigned to this job. To qualify for this job, however, a team member must be able to perform its essential functions with or without reasonable accommodation. Under no circumstances may this job description be construed as altering the at-will nature of the employment relationship between TBA and any team member.

EOE