Manufacturing Quality Engineer

Terra Sonic International; Marietta (OH); On-site; USD 65,000 - 105,000; Full time

Job summary

Terra Sonic International in Marietta, OH, is seeking a Quality Engineer to develop and maintain quality systems for sonic drill rigs, components, and assemblies. You will collaborate with Engineering, Manufacturing, Purchasing, and Service to identify risks and prevent defects.

The ideal candidate has strong mechanical and manufacturing quality experience, plus problem-solving skills and knowledge of hydraulic, structural, mechanical, electrical, and welded components used in heavy equipment.

Qualifications

• 3–5 years in quality engineering or manufacturing quality.
• Ability to interpret drawings, GD&T, and BOMs.
• Experience with calibration/instrumentation: calipers, micrometers, CMM.
• Knowledge of machining, welding, hydraulics and assembly processes.
• Strong problem-solving and communication on manufacturing floor.

Responsibilities

• Quality engineering & manufacturing support: develop, implement, and maintain quality plans and inspection procedures.
• Review drawings, BOMs, and processes to identify quality risks and inspection requirements.
• Establish inspection/testing methods for materials, components, and finished rigs.
• Support production in resolving quality issues and provide guidance on acceptance criteria.
• Perform first-article, in-process, and final inspections as required.
• Verify dimensional accuracy and workmanship of assemblies.
• Verify welding and fabrication quality per requirements and standards.
• Ensure calibration/control of measuring/testing equipment.

Skills

Quality engineering

Manufacturing quality

Root-cause analysis

Problem solving

Communication

MS Office

Tools

Calipers

Micrometers

Height gauges

CMM

ERP/MRP

Job description

Quality Engineer – Sonic Drill Rig Manufacturing

Position Summary

The Quality Engineer is responsible for developing, implementing, and maintaining quality systems and processes that ensure sonic drill rigs, components, and assemblies meet engineering specifications, customer requirements, applicable standards, and company quality objectives.

This position works closely with Engineering, Manufacturing, Purchasing, Welding/Fabrication, Assembly, Service, and Suppliers to identify and prevent quality issues, improve manufacturing processes, reduce defects and rework, and support the continuous improvement of sonic drilling equipment.

The ideal candidate has strong mechanical and manufacturing quality experience, excellent problem-solving skills, and an understanding of hydraulic, structural, mechanical, electrical, and welded components used in heavy equipment or drilling machinery.

Key Responsibilities

• Quality Engineering & Manufacturing Support
• Develop, implement, and maintain quality control plans, inspection procedures, work instructions, and process standards for sonic drill rigs and components.
• Review engineering drawings, specifications, bills of materials, and manufacturing processes to identify quality risks and inspection requirements.
• Establish appropriate inspection and testing methods for incoming materials, fabricated components, machined parts, purchased components, subassemblies, and completed drill rigs.
• Support production personnel in resolving quality issues and provide technical guidance on inspection and acceptance criteria.
• Perform first-article, in-process, and final inspections as required.
• Verify dimensional accuracy, fit, function, alignment, and workmanship of mechanical and structural assemblies.
• Support inspection of hydraulic systems, piping, fittings, cylinders, pumps, motors, valves, and other critical components.
• Verify welding and fabrication quality in accordance with engineering requirements and applicable standards.
• Ensure appropriate calibration and control of measuring and test equipment.

Nonconformance & Corrective Action

• Identify, document, and disposition nonconforming materials, components, and finished products.
• Lead root-cause analysis using methods such as 5 Why, Fishbone/Ishikawa, Pareto analysis, and 8D.
• Develop and implement corrective and preventive actions (CAPA).
• Track quality issues through closure and verify the effectiveness of corrective actions.
• Analyze recurring defects, warranty issues, rework, scrap, and field failures to identify systemic problems.
• Work with Engineering and Manufacturing to implement design or process improvements.
• Support supplier qualification and evaluation activities.
• Develop incoming inspection requirements for critical purchased components and materials.
• Work with suppliers to resolve quality problems and implement corrective actions.
• Review supplier inspection reports, certificates of compliance, material certifications, and other quality documentation.
• Participate in supplier audits when required.
• Monitor supplier quality performance and identify opportunities for improvement.

Process Improvement

• Analyze manufacturing processes to identify sources of variation and quality risk.
• Lead or participate in continuous improvement, Lean Manufacturing, and Six Sigma initiatives.
• Develop process capability studies and statistical process control (SPC) where appropriate.
• Use quality data to identify trends and prioritize improvement activities.
• Reduce scrap, rework, warranty claims, and manufacturing defects.
• Participate in PFMEA development and review, control plan development, and process risk assessments.
• Product Testing & Validation
• Develop and support inspection and functional testing requirements for completed sonic drill rigs.
• Participate in testing of hydraulic, mechanical, electrical, and structural systems.
• Assist with investigation of equipment failures occurring during factory testing, commissioning, or field operation.
• Document test results and verify that corrective actions are completed before equipment release.
• Support field service and engineering teams in troubleshooting customer-reported quality and reliability issues.

Documentation & Quality Systems

• Maintain accurate quality records, inspection reports, nonconformance reports, corrective action records, and other quality documentation.
• Support internal and external audits.
• Ensure manufacturing processes comply with applicable company procedures, customer requirements, and industry standards.
• Assist in maintaining and improving the organization's Quality Management System.
• Support preparation and maintenance of quality metrics and management reports.

Key Performance Indicators

The Quality Engineer may be measured on:

• Scrap and rework rates
• Customer complaints and warranty claims
• Supplier quality performance
• Nonconformance closure time
• On-time completion of inspection and quality activities
• Cost of poor quality
• Manufacturing process capability
• Reduction in recurring quality issues

Required Qualifications

• 3–5 years of experience in quality engineering or manufacturing quality, preferably in heavy equipment, construction equipment, drilling equipment, machinery, or a similar industrial environment.
• Strong ability to interpret mechanical engineering drawings, GD&T, specifications, and bills of materials.
• Experience with dimensional inspection equipment such as calipers, micrometers, height gauges, gauges, and CMM equipment where applicable.
• Working knowledge of manufacturing processes including machining, welding, fabrication, assembly, and hydraulic systems.
• Experience with root-cause analysis and corrective action methodologies.
• Strong problem-solving and analytical skills.
• Ability to communicate effectively with production employees, engineers, suppliers, and management.
• Proficiency with Microsoft Office and quality/manufacturing documentation systems.

Preferred Qualifications

• Experience with sonic drilling equipment, drill rigs, heavy machinery, or mobile equipment.
• Knowledge of hydraulic systems and troubleshooting.
• Knowledge of welding inspection and fabrication processes.
• Familiarity with GD&T and tolerance stack-up analysis.
• Experience with PFMEA, Control Plans, SPC, MSA, and PPAP.
• ASQ Certified Quality Engineer (CQE) or similar quality certification.
• Lean Six Sigma Green Belt or Black Belt certification.
• Welding inspection certification such as AWS CWI is a plus.
• Experience working with ISO 9001 or similar Quality Management Systems.
• Experience with ERP/MRP and quality management software.
• Familiarity with field failure analysis and warranty investigations.

The successful candidate should have a working understanding of:

• Mechanical and structural assemblies
• Hydraulic systems and components
• Welding and metal fabrication
• Machining and dimensional inspection
• GD&T and engineering drawings
• Material specifications and certifications
• Fasteners and bolted joints
• Bearings, shafts, gears, and mechanical power transmission
• Electrical and control-system interfaces
• Assembly and functional testing
• Failure Mode and Effects Analysis (FMEA)
• Statistical Process Control (SPC)
• Measurement System Analysis (MSA)
• Root-cause analysis
• Corrective and preventive action
• Supplier quality management

Core Competencies

• Strong attention to detail
• Analytical and data-driven decision making
• Hands-on problem solving
• Mechanical aptitude
• Ability to work effectively on the manufacturing floor
• Strong communication and interpersonal skills
• Ability to prioritize multiple quality issues
• Ownership and accountability
• Ability to work collaboratively across Engineering, Manufacturing, Purchasing, and Service

This position is primarily based in a manufacturing environment and requires regular interaction with production and assembly operations. The Quality Engineer may be required to work around heavy machinery, welding operations, hydraulic systems, machining equipment, and completed drill rigs.

The position may require occasional travel to suppliers, customer sites, trade shows, or field locations to support quality investigations, equipment commissioning, warranty issues, or supplier development.

Physical Requirements

• Ability to regularly walk through manufacturing and assembly areas.
• Ability to inspect large mechanical assemblies and heavy equipment.
• Ability to climb, bend, kneel, and work around machinery as required for inspection activities.
• Ability to safely use inspection and measurement equipment.
• Ability to comply with all applicable workplace and equipment safety requirements.

Success in the First 90 Days

Within the first 90 days, the Quality Engineer is expected to:

• Become familiar with the company's sonic drill rigs, manufacturing processes, and quality requirements.
• Develop working relationships with Engineering, Manufacturing, Purchasing, Assembly, and Service teams.
• Understand major product quality risks and recurring manufacturing issues.
• Establish a baseline of key quality metrics.
• Take ownership of assigned nonconformances and corrective actions.
• Identify opportunities to reduce rework, scrap, and recurring defects.
• Begin improving inspection and quality-control processes for critical assemblies and components.