Plant Quality Manager

Position: Plant Quality Manager

Job Summary: The Plant Quality Manager is responsible for developing, implementing, and driving the overall quality strategy for the manufacturing plant. The role ensures that products consistently meet customer requirements through robust supplier quality management, process quality control, new product introduction (NPI), product quality assurance, and customer quality management.

The incumbent will lead the Quality function by establishing a culture of quality excellence, driving continuous improvement, reducing the Cost of Poor Quality (COPQ), and ensuring compliance with customer, regulatory, and international quality standards.

Key Responsibilities:

Supplier Quality Management

• Develop and implement supplier quality strategies to ensure incoming materials and components consistently meet quality requirements.
• Establish supplier qualification, approval, and periodic evaluation processes.
• Lead supplier audits and supplier development initiatives.
• Monitor supplier quality performance using KPIs such as PPM, on-time corrective actions, and rejection rates.
• Drive Supplier Corrective Action Requests (SCAR) and verify implementation effectiveness.
• Collaborate with Procurement and Engineering for supplier selection, qualification, and continuous improvement.
• Reduce supplier-related quality issues through preventive quality planning and supplier capability enhancement.

Process Quality

• Establish robust process quality controls throughout manufacturing operations.
• Develop Control Plans, Process Flow Diagrams, PFMEA, inspection standards, and process validation requirements.
• Ensure Statistical Process Control (SPC) and process capability (Cp/Cpk) are effectively implemented.
• Lead root cause analysis using structured methodologies such as 8D, 5 Why, Fishbone Diagram, Pareto Analysis, and DOE where applicable.
• Monitor and improve First Pass Yield (FPY), process capability, defect rates, scrap, and rework.
• Ensure calibration systems and measurement equipment comply with quality requirements.
• Promote error-proofing (Poka-Yoke) and mistake prevention across manufacturing processes.

New Product Introduction (NPI)

• Lead all quality activities during New Product Introduction from prototype through production launch.
• Participate in design reviews and manufacturability assessments.
• Ensure completion of APQP deliverables where applicable.
• Approve PFMEA, Control Plans, Process Validation, and inspection methods before production release.
• Review and approve First Article Inspection (FAI) reports.
• Coordinate Production Part Approval Process (PPAP) submissions where required.
• Ensure smooth transition from development to mass production while achieving quality, delivery, and cost objectives.
• Identify and mitigate quality risks during product industrialization.

Product Quality

• Ensure all manufactured products conform to engineering drawings, specifications, and customer requirements.
• Oversee incoming, in-process, final inspection, and outgoing quality assurance activities.
• Develop quality plans for critical characteristics and special processes.
• Monitor product quality performance through data analysis and trend monitoring.
• Drive defect reduction initiatives using Lean Manufacturing and Six Sigma methodologies.
• Reduce internal rejection, scrap, rework, and Cost of Poor Quality (COPQ).
• Ensure robust traceability and product identification systems.

Customer Quality

• Serve as the primary quality interface with customers.
• Manage customer complaints and ensure timely closure using structured problem-solving methodologies.
• Lead customer audits and ensure successful audit outcomes.
• Track customer quality metrics including Customer PPM, warranty claims, and complaint resolution.
• Drive corrective and preventive actions (CAPA) to eliminate recurring issues.
• Improve customer satisfaction through proactive quality improvement initiatives.
• Support business development by demonstrating strong quality systems and customer confidence.

Quality Management System (QMS)

• Lead implementation and continual improvement of the Quality Management System.
• Ensure compliance with ISO 9001 and applicable industry/customer standards (e.g., IATF 16949, AS9100, ISO 13485).
• Plan and conduct internal audits and coordinate external certification and customer audits.
• Maintain quality documentation, procedures, and work instructions.
• Ensure effective document control and change management.

Continuous Improvement

• Develop and execute plant quality improvement roadmaps.
• Lead Lean, Six Sigma, Kaizen, and operational excellence initiatives.
• Drive cross-functional problem-solving and process optimization.
• Establish data-driven quality dashboards and management reviews.
• Promote a culture of prevention, accountability, and continuous improvement.

Team Leadership

• Lead, mentor, and develop the Quality organization, including Supplier Quality, Process Quality, Customer Quality, Incoming Inspection, Metrology, and Quality Engineering teams.
• Build technical competency through structured training and coaching.
• Establish performance objectives and succession planning for the Quality team.
• Foster collaboration across Production, Engineering, Supply Chain, and Operations.

Key Performance Indicators (KPIs)

Supplier Quality

• Supplier PPM.
• Incoming rejection rate.
• Supplier audit scores.
• SCAR closure effectiveness.
• Supplier on-time corrective action closure.

Process Quality

• First Pass Yield (FPY).
• Process capability (Cp/Cpk).
• Scrap rate.
• Rework rate.
• Internal defect rate.
• Overall Equipment Effectiveness (quality component).

New Product Introduction

• First-time-right product launches.
• PPAP/FAI approval success.
• NPI milestone adherence.
• Launch quality performance.
• Time to production readiness.

Product Quality

• Internal PPM.
• Cost of Poor Quality (COPQ).
• Final inspection acceptance rate.
• Product reliability performance.
• Warranty claims.

Customer Quality

• Customer PPM.
• Customer complaints.
• Customer audit performance.
• On-time CAPA closure.
• Customer satisfaction score.

Working Environment

• Manufacturing plant with regular engagement on the shop floor.
• Frequent interaction with customers, suppliers, engineering, operations, and senior leadership.
• Occasional domestic and international travel for supplier audits, customer visits, and quality reviews.

Requirements:

Required Qualifications

• Bachelor's degree in Mechanical Engineering
• 12 to 15 years of experience in precision manufacturing, with at least 5 years in a senior quality leadership role.

Technical Competencies

• Strong knowledge of precision machining and manufacturing processes.
• Expertise in Quality Management Systems (ISO 9001; IATF 16949, AS9100, or ISO 13485 as applicable).
• Advanced understanding of:
• GD&T and engineering drawings
• APQP, PPAP, PFMEA, Control Plans
• SPC and MSA
• Process capability studies (Cp/Cpk)
• Root cause analysis and CAPA
• Lean Manufacturing and Six Sigma
• Metrology and calibration systems
• Supplier quality management and development
• Risk management and quality planning
• Proficiency in ERP/MES systems and quality analytics.