Lead Manufacturing Quality (Electronics Manufacturing)

Role & responsibilities

Manufacturing Quality Assurance

• Monitor and control quality across critical BLDC motor processes:
• Stator winding, coil resistance, and insulation quality
• Magnet assembly, rotor balancing & alignment.
• Shaft press-fit, bearing assembly & torque checks.
• End-of-line (EOL) testing (No-load current, back-EMF, KV rating, torque, vibration, noise level)
• Develop and implement inspection standards for incoming materials such as magnets, copper wire, bearings, laminations, housings, PCBs, sensors, and fasteners.
• Ensure compliance with industry standards for motor performance, electrical safety, and reliability.

Quality Control & Testing

• Establish quality checkpoints, sampling plans, and control plans at each manufacturing stage.
• Monitor SPC for critical parameters (resistance, back-EMF, total harmonic distortion, run-out, vibration).
• Lead failure analysis for defective motors using tools like:
• 5-Why
• 8D
• Ishikawa
• Fault Tree Analysis (FTA)
• Validate EOL testers and measurement systems through MSA, GRR, and calibration.

Process Quality & Problem Solving

• Conduct root-cause analysis on process deviations such as winding failures, noise/vibration issues, magnet shifting, torque drop, or electrical leakage.
• Support Engineering to improve motor designs for manufacturability (DfM, DfA).
• Lead CAPA implementation and ensure long-term closure.

Continuous Improvement

• Drive yield improvement, defect reduction, and scrap minimization projects.
• Implement poka-yoke solutions across assembly lines.
• Support automation initiatives for winding, assembly, and testing.
• Introduce best practices from Lean, Six Sigma, and TPM.

Documentation & Compliance

• Maintain quality documentation: SOPs, work instructions, PFMEA, control plans, PPAP documents.
• Record and track FPY, defect trends, customer complaints, COPQ, and reliability data.
• Prepare quality dashboards and present weekly/monthly reports to management.

Cross-Functional Collaboration

• Work closely with Production, Maintenance, R&D, and Supplier Quality to resolve issues.
• Support NPI builds, pilot runs, and validation for new BLDC motor models.
• Coordinate with vendors for quality improvement of magnets, bearings, windings, PCBs, and mechanical components.

Team Leadership

• Lead quality inspectors and technicians across multiple manufacturing lines.
• Train shop-floor teams on defect identification, visual standards, and quality controls.

Preferred candidate profile

• Strong understanding of BLDC motor construction, winding practices, and electrical performance parameters.
• Assertive in dealing with Internal and External Customers
• Proficiency in quality tools: FMEA, MSA, SPC, PPAP, 8D, CAPA.
• Experience with measurement systems (EOL testers, LR-IR, Load/No Load tests, NVH testers).
• Strong analytical, leadership, and communication skills.
• Bachelor's degree in mechanical, Electrical, Mechatronics, or Industrial Engineering.
• 1016 years of experience in manufacturing quality, with at least 2 years in BLDC motors, electric motors, automotive components, or electromechanical assemblies.
• Experience with high-volume production environments is preferred.