Manufacturing Quality Senior Analyst

Job Description

In-Process Quality Management

• Lead in-process quality inspection and verification activities across manufacturing lines.
• Ensure compliance with Control Plans, SOPs, Process Flow, PFMEA, and work instructions.
• Monitor critical process parameters and quality checkpoints.
• Ensure First Piece Approval (FPA) and process setup verification before production release.
• Drive adherence to quality gates and process controls.

Quality Issue Management

• Lead investigations of in-process defects, line rejections, and process deviations.
• Conduct Root Cause Analysis using 8D, 5 Why, Fishbone, and other quality tools.
• Implement and monitor containment, corrective, and preventive actions.
• Verify effectiveness of corrective actions and ensure sustainable closure.

Process Audits & Compliance

• Conduct Layered Process Audits (LPA), Process Audits, and Product Audits.
• Ensure compliance with ISO 9001, QMS requirements, and customer specifications.
• Support internal, customer, and certification audits.
• Maintain audit records, inspection reports, and quality documentation.

Manufacturing Process Improvement

• Analyze process rejection trends and identify improvement opportunities.
• Drive initiatives to reduce defects, rework, scrap, and Cost of Poor Quality (COPQ).
• Support Lean Manufacturing, Kaizen, Six Sigma, and Operational Excellence projects.
• Implement mistake-proofing (Poka-Yoke) and process control improvements.

New Product Introduction (NPI)

• Support Proto Builds, Pilot Builds, and Production Readiness Reviews.
• Participate in PFMEA, Control Plan, and process validation activities.
• Ensure quality requirements are incorporated during new product introduction.
• Support Gate Reviews and manufacturing process qualification.

Cross-Functional Coordination

• Work closely with Production, Manufacturing Engineering, Supplier Quality, Incoming Quality, and Customer Quality teams.
• Participate in daily production review meetings and quality escalation discussions.
• Support customer complaint investigations related to manufacturing defects.
• Drive timely closure of manufacturing quality concerns.

Qualifications

• Bachelor's Degree / Diploma in Mechanical, Electrical, Electronics, Production, or Industrial Engineering.
• 4 to 7 years of experience in Manufacturing Quality, IPQA, Production Quality, or Quality Assurance.
• Experience in assembly, fabrication, electrical panel manufacturing, or industrial equipment manufacturing.

Required Skills

• In-Process Quality Assurance
• PFMEA, Control Plan & Process Flow
• Root Cause Analysis (8D, 5 Why, Fishbone)
• Process Auditing
• SPC & Process Capability Analysis
• GD&T and Drawing Interpretation
• Measurement System Analysis (MSA)
• SAP/ERP Knowledge
• Quality Reporting & Data Analysis
• Lean Manufacturing & Continuous Improvement

Preferred Experience

• Electrical Panel Assembly
• UPS, ATS, PDU, Thermal Products
• Sheet Metal Fabrication
• Wiring & Harness Assembly
• Torque-Controlled Assembly Processes
• Functional Testing & Validation
• Manufacturing Process Audits

Key Performance Indicators (KPIs)

• First Pass Yield (FPY)
• In-Process Rejection Reduction
• Rework & Scrap Reduction
• Process Audit Compliance
• Internal Defect Reduction
• Corrective Action Closure Effectiveness
• Customer Complaint Reduction Related to Manufacturing Defects
• COPQ Reduction

Competencies

• Strong Analytical & Problem-Solving Skills
• Leadership & Team Coordination
• Decision-Making Ability
• Effective Communication
• Process Improvement Mindset
• Ownership & Accountability
• Customer Focus