Job Title: Quality Control and Monitoring Systems Engineer
Job Summary:
The Quality Control and Monitoring Systems Engineer Manager is responsible for overseeing the strategic development, implementation, and optimization of quality control and monitoring systems in manufacturing and industrial environments. This managerial role involves leading teams of engineers and technicians to ensure that quality systems are aligned with business objectives, regulatory standards, and continuous improvement goals. The manager will drive operational excellence, improve system performance, and ensure that products consistently meet or exceed quality standards while managing budgets, resources, and cross-functional collaboration.
Key Responsibilities:
Leadership and Team Management:
- Lead and manage a team of quality control engineers and technicians, providing guidance, training, and mentorship to foster professional development and high performance.
- Set clear objectives, monitor team progress, conduct performance reviews, and manage team dynamics to ensure project and operational goals are met.
- Foster a collaborative environment by encouraging teamwork, knowledge sharing, and the exchange of best practices to drive continuous improvement.
Quality Control System Design and Optimization:
- Lead the design, implementation, and continuous improvement of quality control and monitoring systems, including automated inspection systems, PLCs, SCADA, sensors, and other measurement technologies.
- Develop strategies for quality control system enhancements to optimize performance, reduce waste, increase efficiency, and ensure products meet all regulatory and quality standards.
- Oversee the integration of new technologies and automation tools to improve monitoring capabilities, data collection, and real-time performance tracking.
Project Management and Execution:
- Manage multiple quality control projects, from planning and design to implementation, ensuring that all milestones are achieved on time, within budget, and in line with technical specifications.
- Coordinate cross-functional teams, including engineering, production, and maintenance departments, to ensure successful project delivery.
- Oversee system commissioning, performance testing, and troubleshooting during the project phases to ensure smooth integration and handover.
Regulatory Compliance and Reporting:
- Ensure that all quality control systems comply with relevant industry regulations, safety standards, and environmental guidelines (e.g., ISO 9001, GMP, FDA).
- Maintain and manage documentation for audits, ensuring traceability of quality data, system configurations, and corrective actions.
- Prepare and deliver detailed reports on quality performance, non-conformities, and corrective actions to senior management, regulatory bodies, and other stakeholders.
Process Optimization and Continuous Improvement:
- Lead process optimization initiatives using Six Sigma, Lean Manufacturing, and other continuous improvement methodologies to reduce defects, improve efficiency, and enhance product quality.
- Analyze quality data and production metrics to identify trends and areas for improvement in both the product quality and manufacturing processes.
- Implement corrective and preventive actions based on root cause analysis to minimize system downtime and improve process efficiency.
Troubleshooting and Root Cause Analysis:
- Lead troubleshooting efforts for complex quality control issues, ensuring the quick identification and resolution of problems with automated inspection systems, sensors, and measurement equipment.
- Use root cause analysis techniques to address quality failures and implement long-term solutions to prevent recurring problems.
- Ensure that effective solutions are applied promptly to maintain product quality and minimize disruptions in production.
Collaboration with Cross-Functional Teams:
- Work closely with operations, engineering, IT, and production teams to ensure that quality control systems are fully integrated into the manufacturing process and aligned with production goals.
- Collaborate with senior leadership to align quality control objectives with the company’s broader goals and strategies.
- Act as a liaison between quality control teams and other departments to resolve quality-related issues and ensure continuous communication across all functions.
Data Management and Reporting:
- Oversee the collection and analysis of quality data from automated systems to assess product quality and system performance.
- Develop key performance indicators (KPIs) to measure quality metrics, including defect rates, yield, and production downtime.
- Use data analysis tools to present actionable insights to management, guiding decisions on process improvements and capital investment.
Resource and Budget Management:
- Manage the budget for quality control systems and projects, ensuring effective allocation of resources for system upgrades, equipment procurement, and personnel training.
- Monitor and report on expenses related to quality control operations and projects, ensuring they remain within the established budget.
Innovation and Technology Integration:
- Research and integrate emerging technologies (e.g., AI-based inspection systems, IoT for predictive maintenance) to improve quality control capabilities and drive innovation.
- Lead the adoption of smart manufacturing technologies and Industry 4.0 practices to improve monitoring, quality assurance, and process control.
Skills and Knowledge Required:
- Expertise in quality control systems, including PLCs, SCADA, HMI, automated inspection systems, and measurement technologies.
- In-depth knowledge of industrial process control, data analysis, and performance monitoring.
- Strong proficiency in statistical analysis and process optimization techniques (e.g., Six Sigma, Lean Manufacturing, Statistical Process Control).
- Experience with regulatory standards and quality management systems (e.g., ISO 9001, GMP, FDA regulations).
- Proven ability to lead teams, manage projects, and collaborate across functions.
- Strong problem-solving and analytical skills, with experience in root cause analysis and corrective actions.
- Familiarity with data analysis software and tools (e.g., Excel, Power BI, SQL, Minitab) for quality control and reporting.
- Strong leadership, communication, and interpersonal skills to engage with stakeholders at all levels.
Educational Qualifications:
- Bachelor’s or Master’s degree in Mechanical Engineering, Industrial Engineering, Electrical Engineering, Quality Assurance, or a related technical field.
- Certifications in quality management systems (e.g., Six Sigma Black Belt, Lean Manufacturing) and process control systems are highly desirable.
Experience:
- 7+ years of experience in quality control, process monitoring, or manufacturing, with at least 3 years in a managerial or leadership role.
- Proven experience in leading quality control projects, managing quality systems, and driving process optimization in an industrial or manufacturing setting.
- Experience with SCADA systems, PLC programming, automated inspection technologies, and industrial control systems.
- Strong background in regulatory compliance, auditing, and preparing quality-related reports for senior management and external bodies.
Tools and Technologies:
- Expertise in PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000).
- Experience with SCADA platforms (e.g., Wonderware, Ignition) and industrial control systems.
- Proficiency in data analysis tools and performance monitoring systems (e.g., Power BI, Minitab, SQL, Excel).
- Familiarity with emerging technologies such as AI for quality inspection, predictive analytics, and IoT-based monitoring.
Other Requirements:
- Strong leadership and communication skills, with the ability to guide teams and influence decision-making at all levels.
- Ability to manage multiple projects simultaneously and adapt to evolving business needs.
- Willingness to travel to different plant sites or facilities to monitor quality processes, ensure compliance, and support system installations.