Job Title: Quality Control and Monitoring Systems Engineer
Job Summary:
The Senior Quality Control and Monitoring Systems Engineer is responsible for overseeing the design, implementation, optimization, and management of quality control systems in manufacturing or industrial environments. This leadership role involves driving quality initiatives, managing complex quality monitoring systems, ensuring compliance with regulatory standards, and leading process improvements to ensure products consistently meet or exceed quality standards. The Senior Engineer will mentor junior engineers, collaborate with cross-functional teams, and lead strategic efforts to enhance product quality, efficiency, and operational excellence.
Key Responsibilities:
Quality Control Systems Strategy and Design:
- Lead the design and implementation of advanced quality control systems, including automated inspection systems, PLCs, SCADA, and sensors to monitor and improve product quality.
- Develop and implement long-term quality control strategies to enhance the manufacturing process and ensure consistency, efficiency, and quality in all products.
- Oversee the integration of new technologies and systems (e.g., IoT, AI, machine learning) into existing quality control processes to increase system performance and data visibility.
Process Optimization and Continuous Improvement:
- Drive continuous improvement initiatives by identifying opportunities to optimize quality control systems and manufacturing processes, aiming to reduce defects, minimize waste, and enhance product consistency.
- Lead the implementation of lean manufacturing, Six Sigma, and other process optimization methodologies to improve overall operational efficiency.
- Analyze system performance data to identify trends, inefficiencies, or bottlenecks in the quality control process and recommend corrective actions.
Team Leadership and Mentorship:
- Lead and manage a team of quality control engineers and technicians, providing guidance, mentorship, and support for their professional development.
- Oversee team performance and provide regular feedback, ensuring high levels of productivity and adherence to quality standards.
- Facilitate training sessions and knowledge-sharing activities to ensure that all team members are up-to-date on new technologies, processes, and industry standards.
Regulatory Compliance and Reporting:
- Ensure that all quality control systems comply with relevant industry regulations and standards (e.g., ISO 9001, FDA, GMP), ensuring product quality and safety.
- Maintain documentation of quality control processes, system configurations, and test results for internal and external audits.
- Prepare and present detailed reports on quality control performance, regulatory compliance, and process improvements for senior management and external stakeholders.
Troubleshooting and Advanced Problem Solving:
- Lead troubleshooting and root cause analysis efforts for complex quality issues and failures in control systems, sensors, or the manufacturing process.
- Provide expert support and technical guidance to resolve issues with quality control systems, minimizing downtime and ensuring minimal impact on production schedules.
- Implement long-term solutions to recurring quality issues and ensure preventive actions are taken to avoid future problems.
Cross-Functional Collaboration:
- Collaborate with operations, engineering, production, and maintenance teams to ensure that quality standards are consistently met across all stages of the production cycle.
- Work closely with R&D teams to integrate new products into the quality control process and ensure new product designs meet required quality standards.
- Provide technical support and guidance to other departments on quality control and monitoring system-related issues, ensuring alignment with overall business objectives.
Data Management and Performance Monitoring:
- Manage the collection, analysis, and interpretation of quality-related data to monitor system performance and product quality.
- Develop and monitor key performance indicators (KPIs) to track quality trends, identify improvement areas, and make data-driven decisions.
- Utilize advanced data analysis tools and reporting systems (e.g., Power BI, SQL, Minitab) to present actionable insights to senior management.
Innovation and Technological Leadership:
- Stay informed about the latest trends, tools, and technologies in quality control, automation, and process monitoring.
- Lead the adoption of emerging technologies such as predictive maintenance, AI-based quality inspection, or blockchain for traceability and quality assurance.
- Foster a culture of innovation within the quality control team by encouraging experimentation with new approaches and technologies to enhance product quality.
Risk Management and Safety:
- Oversee risk assessments related to quality control systems and processes, ensuring all safety standards and guidelines are followed.
- Ensure that automation systems, sensors, and other quality control equipment are operated safely and are compliant with environmental and health regulations.
- Establish safety protocols for handling critical quality control equipment, ensuring that team members are trained to use them effectively and safely.
Skills and Knowledge Required:
- Expertise in quality control systems, including PLCs, SCADA, HMI, sensors, and automated inspection systems.
- Strong understanding of industrial process control and monitoring systems, including experience with data analysis and performance monitoring.
- In-depth knowledge of industry regulations and quality standards, such as ISO 9001, FDA, GMP, and others.
- Experience with advanced technologies like machine learning, IoT, or AI applied to quality control processes.
- Proficiency in statistical analysis and process optimization methods (e.g., Six Sigma, Lean Manufacturing, Statistical Process Control).
- Strong troubleshooting, analytical, and problem-solving skills to address complex quality issues in manufacturing and production environments.
- Strong leadership skills, with experience managing teams, providing mentorship, and overseeing quality improvement initiatives.
- Excellent communication skills, with the ability to present complex data and technical information to senior management and other stakeholders.
Educational Qualifications:
- Bachelor’s or Master’s degree in Mechanical Engineering, Industrial Engineering, Electrical Engineering, Quality Assurance, or a related technical field.
- Certifications in Six Sigma, Lean Manufacturing, ISO 9001, or other quality-related certifications are highly desirable.
Experience:
- 7+ years of experience in quality control, process monitoring, or manufacturing, with at least 3 years in a senior or leadership role.
- Proven track record of leading quality control initiatives, optimizing systems, and ensuring regulatory compliance in manufacturing or industrial settings.
- Experience with PLC programming, SCADA systems, automated inspection technologies, and process control systems.
- Strong experience with data analysis tools (e.g., Power BI, SQL, Minitab) and statistical process control.
Tools and Technologies:
- Proficiency in quality control instruments (e.g., micrometers, calipers, spectrometers) and PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000).
- Experience with SCADA platforms (e.g., Wonderware, Ignition) and industrial automation systems.
- Familiarity with data analysis software (e.g., Minitab, Excel, Power BI) and statistical tools for quality control.
- Knowledge of emerging technologies in process monitoring and automation (e.g., IoT, AI, machine learning).
Other Requirements:
- Strong leadership, communication, and interpersonal skills.
- Ability to manage multiple high-priority projects simultaneously.
- Strong organizational skills, with attention to detail and a focus on continuous improvement.
- Willingness to travel to various plant sites or production facilities to monitor quality processes and ensure compliance.