Process Quality Engineer - AWS

EControls; San Antonio, Northern (TX, KY); Hybrid; USD 75,000 - 110,000; Full time

Job summary

EControls seeks a Process Quality Engineer to join our San Antonio, TX team. You will lead quality initiatives in high-volume manufacturing for automotive components, including wiring harnesses, with hands-on process control and problem solving.

Responsibilities include implementing SPC, PPAP support, PFMEA, and 8D investigations, mentoring inspectors, and driving continuous improvement across manufacturing processes to ensure product conformance and uptime.

Qualifications

• B.S. in Electrical or Mechanical Engineering.
• 5+ years of high volume electronic manufacturing, preferably automotive.
• Six Sigma training or certification.
• Knowledge of FMEA, PPAP, MSA, Fault Tree Analysis, DVT, Product Return Rate Analysis, FRACAS and Root Cause Failure Analysis is required.
• Ability to communicate effectively with global customers, design/production engineering, and manufacturing.
• Experience with lean manufacturing and Six Sigma methodologies.
• Experience with Mini-Tab preferred.
• Experience supporting ISO, TS, CSA, and/or UL.

Responsibilities

• Support Manufacturing Operations — design experiments to develop optimum production processes (manual/automatic assembly, testing).
• Plan and develop capacity utilization strategy for assembly of electrical components.
• Troubleshoot root causes for equipment and process problems.
• Create work instructions & procedures and update existing.
• Lead safety initiatives and OSHA-related tasks.

Skills

5+ years automotive experience

Wire Harness manufacturing

Lean manufacturing

Six Sigma

MiniTAB

ISO/TS/CSA/UL knowledge

Education

B.S. in Electrical or Mechanical Engineering

Tools

MiniTAB

Job description

Description

EControls is a global provider of innovative, state-of-the-art integrated controls solutions for internal combustion engines and electric drive systems in the off-highway, on-highway, and stationary equipment markets. EControls designs world-class, full-authority engine management systems for major OEMs around the world. Our global engine development labs and engineering staff offer full-range support, from design guidance for base engine conversion to hardware, software, and engine calibration to meet each application's specific requirements.

We are passionate about customer satisfaction and service. We fearlessly engage in any effort that will eliminate our customers’ risk and clear a path to their success. We immerse ourselves in our customers’ world, reveal unknowns and deliver integrated solutions.

We are seeking a Process Quality Engineer to work at our AWS location in San Antonio, Texas. Candidate must be a self-starter, hands-on individual with 5+ years of automotive industry experience. Experience with Wire Harness manufacturing is a preferred.

Key Job Elements

Fulfill the role of Quality Engineer in:

• Process Quality
  • RTF Metric reporting and problem solving.
  • Support and instruct Quality Inspectors.
  • Identify root cause and respond with corrective action.
  • Develop and execute plans for quality control to ensure constant manufacturing continuity and product conformance.
  • Review, supervise and review quality control plans.
  • Participate as Material Review Board member to review Non-Conforming Material as suitable.
  • Initiate purge and sort activities along with supervise quality documents.
  • Develop and execute statistical process controls utilizing appropriate quality tools plus statistical techniques
    • DMAIC: Define, measure, analyze, improve and control
    • PDCA: Plan, do, check, act
    • Problem solving (product/process)
• APQP: Advanced Product Quality Planning
  • Review drawings, routings, work orders, work instructions and various related production and development plans for quality requirements.
  • Process flow diagrams, Work instructions, control plans and PFMEA
• PPAP: Production Part Approval Process: Assist qualification of new manufactured quality products.
• Customer Quality: Apply 8D Methodology to investigate all Customer complaints and issues.

Fulfill the role of Manufacturing Engineer in:

• Change management: Drive execution of SBR, ECR/ECO, DCO, DEV, 8D, NCR and Inspections.
• Continuous Improvement: Optimizer Value streams for operational excellence and lean manufacturing:
  • Poka Yoke / Mistake proofing
  • Capacity (current/forecast)
  • Standard work / Line balance
  • Kaizen (mini/major events)
  • 5S and Visual Standards
  • SMED: Single Minute Exchange of Dies
• Support Manufacturing Operations
  • Design experiments to develop optimum production processes - manual assembly, automated assembly, press operations, automated inspection, testing, etc.
  • Supervise ME Technicians to identify and solve production/quality issues
  • Plan and develop processes and capacity utilization strategy for assembly operation of electrical components.
  • Ensure production readiness of key processes.
  • Troubleshoot root cause for equipment and process related problems.
  • Develop appropriate secondary manufacturing processes.
  • Create work instructions & procedures and update existing.
  • Conduct time studies, modify BOMs and routings.
  • Work with suppliers on component issues.
  • Workplace design (Tools / Fixtures / Cells) and Plant layout.
  • Material presentation and packaging.
• Support New Product Development and Continuous Improvement Efforts
  • Class 2 project ownership for Operations.
  • Class 1 support Advanced Manufacturing Engineering and Manufacturing Test Engineering.
• Support Safety and Training
  • Establish solutions to safety near misses, Path cards (Ergonomics).
  • Lead and participate in OSHA teams.
  • Train the trainers and train operators as required.
• Personal Development
  • Learn how our products work and how they are used.

Qualifications

• B.S. in Electrical or Mechanical Engineering or B.S.E.T. Electrical or Mechanical Engineering
• A minimum of 5 years of high volume Electronic Manufacturing, preferably for automotive applications
• Prefer Six Sigma training or certification
• Knowledge of FMEA, PPAP, MSA, Fault Tree Analysis, DVT (Design Verification Testing), Product Return Rate Analysis, FRACAS and Root Cause Failure Analysis is required.
• Ability to communicate effectively with global customers, design/production engineering, and manufacturing.
• Experience with lean manufacturing and Six Sigma methodologies.
• Experience with Mini-Tab preferred.
• Experience supporting ISO, TS, CSA, and/or UL.