Senior Quality Engineer

Forge Talent Group; Newton Aycliffe; On-site; GBP 65,000 - 90,000; Full time

Benefits offered by this job

Job summary

Forge Talent Group seeks an experienced Senior Quality Engineer to lead quality across NPI and Plant Quality, ensuring robust development, validation and continuous improvement of products and processes.

You will drive APQP, PPAP and PFMEA, coordinate MSA and process capability, and act as the quality liaison with customers and suppliers to secure containment and effective corrective actions.

Qualifications

• Degree or equivalent in engineering, manufacturing, quality or related discipline.
• Significant quality engineering experience in automotive/advanced manufacturing.
• Strong knowledge of APQP, PPAP, PFMEA, Control Plans, MSA and process capability.
• Solid understanding of IATF 16949, ISO 9001 and customer-specific requirements.
• Experience leading structured problem-solving and corrective actions.
• Experience dealing with customers and suppliers.

Responsibilities

• Lead quality activities for NPI projects from quotation to SOP.
• Drive APQP, PPAP submissions and customer approvals.
• Lead PFMEA reviews and develop control plans.
• Coordinate MSA, validation, and process capability activities.
• Lead investigations into customer complaints and supplier quality issues.
• Develop and deliver quality improvement projects aligned with plant objectives.

Skills

APQP

PPAP

PFMEA

Control Plans

MSA

Process Capability

IATF 16949

ISO 9001

Root Cause Analysis

Customer & Supplier Interaction

Education

Degree / HNC / HND in engineering or quality

Job description

We are looking to recruit an experienced Senior Quality Engineer to join our client's team on a permanent basis.

Job Purpose

To lead quality activities associated with New Product Introduction (NPI) and Plant Quality, ensuring products and processes are robustly developed, validated, controlled and continuously improved. The role acts as the key quality representative during project launches while driving quality performance across manufacturing operations, customer requirements, supplier quality issues and continuous improvement initiatives. To ensure compliance with customer-specific requirements, IATF 16949, ISO 9001 and internal quality standards, while supporting the achievement of operational, quality and customer satisfaction objectives.

Key Responsibilities

New Product Introduction (NPI)

• Serve as the Quality lead for NPI projects from quotation through to Start of Production (SOP).
• Support Advanced Product Quality Planning (APQP) activities and ensure quality deliverables are completed to programme timing.
• Lead Production Part Approval Process (PPAP) submissions and customer approval activities.
• Facilitate PFMEA reviews and develop control plans using the structured AIAG–VDA 7‑step methodology to drive robust, risk‑focused process control.
• Ensure customer and product quality requirements are effectively incorporated into manufacturing processes.
• Coordinate Measurement System Analysis (MSA), validation and process capability activities.
• Support prototype, pilot and launch builds, including launch containment and early production quality monitoring.
• Act as a key customer quality contact during product introduction phases.

Plant Quality

• Lead investigations into customer complaints, internal non‑conformances and supplier‑related quality issues.
• Drive structured root cause analysis using appropriate methodologies, including 8D, 5 Why and Ishikawa.
• Ensure robust containment, corrective and preventive actions are implemented, documented and verified for effectiveness.
• Monitor quality performance indicators, including PPM, scrap, rework, customer complaints and cost of poor quality.
• Lead continuous improvement activity to improve product and process quality and reduce variation.
• Establish and maintain effective process controls to minimise defects and recurrence.
• Support production teams in resolving significant or recurring quality concerns.
• Develop and deliver quality improvement projects aligned with plant objectives.

Customer & Supplier Quality

• Act as the primary customer quality interface for allocated accounts.
• Lead customer visits, audits and quality performance reviews.
• Coordinate customer complaint, warranty and field‑return investigations where applicable.
• Support supplier quality performance improvement activities.
• Review supplier corrective actions and verify effective resolution.
• Participate in supplier audits and supplier development initiatives.

Quality Systems & Compliance

• Support the maintenance and continual improvement of the Quality Management System.
• Ensure compliance with IATF 16949, ISO 9001, customer‑specific requirements and internal standards.
• Conduct internal audits and support customer, certification and other external audits.
• Maintain quality documentation, including procedures, process flow charts, PFMEAs and control plans.
• Ensure lessons learned are captured, communicated and incorporated into future quality planning.

Leadership & Development

• Provide technical guidance and mentoring to Quality Engineers, Quality Inspectors and cross‑functional colleagues.
• Promote a culture of quality ownership and right‑first‑time performance throughout the business.
• Lead quality‑related training and awareness activities.
• Support the development and implementation of site quality strategies.
• Deputise for the Quality Manager when required.

Key Performance Indicators

• Customer PPM and complaint performance.
• Internal defect, scrap and rework reduction.
• NPI launch quality and containment performance.
• On‑time and right‑first‑time PPAP submission.
• Audit completion, findings and compliance performance.
• Corrective action closure and effectiveness.
• Cost of Poor Quality reduction.Supplier quality performance improvement.

Knowledge, Qualifications & Experience

Essential

• Degree, HNC/HND or equivalent qualification in engineering, manufacturing, quality or a related discipline.
• Significant Quality Engineering experience within an automotive or advanced manufacturing environment.
• Strong working knowledge of APQP, PPAP, PFMEA, Control Plans, MSA and process capability.
• Strong understanding of IATF 16949, ISO 9001 and customer‑specific requirements.
• Experience leading structured problem‑solving and corrective action programmes.
• Experience dealing directly with customers and suppliers.
• Strong analytical, data interpretation and report‑writing capability.
• Internal Auditor qualification or equivalent practical auditing experience.

Desirable

• Lead Auditor qualification.
• Six Sigma Green Belt or equivalent continuous improvement qualification.
• Experience of metal pressing, tooling, assembly or automotive manufacturing processes.
• Experience mentoring or supervising Quality Engineers, Technicians or Inspectors.