Sr. Quality Engineer

Kapco Inc.; Town of Grafton (WI); On-site; USD 90,000 - 120,000; Full time

Job summary

Kapco Metal Stamping in Grafton, WI, is seeking a Senior Quality Engineer to lead quality systems development and drive continuous improvement in our manufacturing operations.

The role focuses on customer quality expectations, APQP activities, PFMEA, MSA, PPAP, and problem-solving across cross-functional teams to ensure product excellence. This position offers growth within a family-oriented culture and exposure to high-profile projects.

Qualifications

• Bachelor’s degree in engineering or related field required.
• Minimum 5 years in quality engineering in a manufacturing environment.
• ASQ CQE or CQA desirable.
• Willing to travel (Domestic/International) up to 20%.

Responsibilities

• Develop, implement quality assurance processes, launch plans, test plans, and inspection procedures.
• Lead corrective action and root cause analysis with cross-functional teams.
• Drive PFMEA, control plans, and process improvements.
• Coach teams on APQP tools and support new product launches.

Skills

Quality engineering

APQP

FMEA

Control Plans

MSA

PPAP

SPC

GD&T

Six Sigma Green Belt

Leadership

Education

Bachelor’s degree in Engineering or related field

Tools

ASQ CQE or CQA

ISO 9000 Auditing

TS 16949 Awareness

Job description

Kapco Metal Stamping is the Midwest’s premier contract manufacturer of metal components, trusted by some of the world’s biggest brands to make precision metal parts. Kapco’s constant investment in modern, state-of-the-art equipment and cutting-edge technology sets us apart from other manufacturers in the industry and helps us deliver the highest quality products to their partners.

Alongside our metal stamping, fabrication, welding, and machining capabilities, Kapco has built a lasting reputation for our family culture based upon six core values: Innovation, Attitude, Integrity, Impact, Accountability, and Safety.

Today, Kapco employs over 600 employees across our family of companies, and we are looking to add to our fast-growing team!

Senior Quality Engineer –Kapco Grafton, WI

If you are driven to succeed with a passion for the professional growth and development of others, our employee-focused company may have the right opportunity for you! Kapco is looking for a Senior Quality Engineer to join our Grafton, WI team. The Senior Quality Engineer is responsible for developing and implementing quality systems, resolving complex quality issues, leading problem-solving initiatives, and driving continuous improvement efforts. This position requires a deep understanding of our customers’ quality standards, requirements, and manufacturing processes.

Primary Responsibilities

• Customer Interface:
  • Serve as the primary point of contact for assigned customers regarding quality concerns, audits, and performance reviews. Ensure customer satisfaction by addressing concerns and ensuring timely resolution of quality issues.
  • Work closely with cross-functional teams, including Operations, Engineering, and Supply Chain to resolve quality issues and implement quality improvements.
  • Monitor supplier portal in the system for customer quality issues and performance (coordinate responses with Quality Manger & functional Operations team members.
• Quality Planning and Strategy:
  • Develop, implement, and maintain quality assurance processes, launch plans, test plans, and inspection procedures to ensure product quality and compliance with standards.
• Problem Solving and Root Cause Analysis:
  • Manage CAR analysis, lead cross-functional teams using problem solving methodologies to address internal and customer quality issues. Create corrective action plans to address process failures and prevent recurrence. Provide structured problem-solving support-reactive (field failure or testing) and preventive (mitigate NPD risk).
• Process Control and Improvement:
  • Develop and maintain process control plans, PFMEA’s and control charts. Drive process improvements to enhance product quality and manufacturing efficiency.
• Training and Support:
  • Support and coach team members on quality standards and expectations. Coach in the use of fundamental APQP tools (PPAP, DFMEA, PFMEA, Process Validation Plans and Production Control Plans).
• Product Launch Support:
  • Support new product introductions by ensuring quality standards are met during pre-production and production phases. Participate in APQP activities and validate PPAP submissions.
  • Assist in the development of dimensional control strategies with customers.
  • Assist in the design and procurement of gages and instruments with customers.
  • Conduct and direct MSA activities on new gauges and precision equipment.
• Metrics and Reporting:
  • Monitor, analyze and improve daily, weekly, and monthly quality metrics such as PPM, Cost of Quality, and Corrective Action timing and response. Report on quality performance and lead initiatives to achieve quality objectives.

  • Document and distribute lessons learned to the organization.

Qualifications

• 5 years of experience in quality engineering and related disciplines including implementing and applying quality tools (APQP, FMEA, Control Plans, MSA, PPAP, SPC, GD&T) and problem-solving techniques (8D, 5-Why, etc.) in a manufacturing environment.
• Bachelor’s degree in engineering or a related field, Industrial or Mechanical Engineering preferred.
• Minimum (5-7) years in an APQP role.
• ASQ CQE or CQA desirable
• Auditor experience (ISO 9000 and TS 16949)
• Structured problem-solving experience (Six Sigma Green Belt or Shainin Red “X” Journeyman) desired.
• Willing to travel (Domestic/International) up to 20%

About Kapco Metal Stamping

Kapco is known for investing in its people and creating a culture of engagement, and is equally as committed to giving back to the community. As an employee, you can expect a goal-oriented compensation structure, excellent benefits including Medical, Dental and Vision Insurance, 401K, Profit Sharing, Vacation, Paid Holidays, an Onsite Wellness Center and Gym Membership. Building on employees’ skill sets and growing them as individuals is a top priority at Kapco. The Kacmarcik Center for Human Performance is focused specifically on delivering an exclusive and proprietary in-house training curriculum designed to develop employees along their career path.

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
This employer is required to notify all applicants of their rights pursuant to federal employment laws.For further information, please review the Know Your Rights notice from the Department of Labor.