QA Engineer

This role encompasses outgoing quality control, failure analysis, customer complaint management, and compliance with automotive quality management systems. The successful candidate will monitor product quality against customer specifications, lead investigations into product failures using systematic problem-solving methodologies, support customer complaint resolution through 8D reporting, ensure compliance with IATF 16949 and ISO 9001 standards, drive process and manufacturing improvements, and maintain quality data and performance dashboards.

Key Responsibilities

1. Outgoing Quality Control

• Monitor outgoing product quality against customer specifications, engineering drawings, and control plans.
• Review inspection results, defect trends, parts per million (PPM) performance, and customer quality requirements.
• Ensure that final inspection and product release processes are effectively implemented.
• Control and disposition nonconforming products before shipment.

2. Failure Analysis and Root Cause Investigation

• Lead investigations into internal and customer-reported product failures.
• Apply systematic root cause analysis (RCA) methodologies, including 5 Whys, Fishbone Diagrams, and Fault Tree Analysis (FTA).
• Conduct dimensional, material, functional, and visual analyses to identify failure mechanisms.
• Drive the implementation of permanent corrective actions and preventive measures to avoid recurrence.

3. Customer Complaint Management

• Support customer complaint investigations and prepare 8D problem-solving reports.
• Ensure timely resolution of customer complaints through effective corrective and preventive actions.
• Support updates to Process Failure Mode and Effects Analysis (PFMEA), Control Plans, Measurement System Analysis (MSA), Statistical Process Control (SPC), and Production Part Approval Process (PPAP) documentation following quality failures.
• Ensure that lessons learned are incorporated into new and existing programs.

4. Automotive Quality Systems and Compliance

• Support customer and internal quality audits.
• Ensure compliance with IATF 16949, ISO 9001, applicable Quality Management System (QMS) requirements, customer-specific requirements (CSRs), and internal quality procedures.
• Support PFMEA, Control Plan, MSA, SPC and PPAP updates following quality failures.

5. Process Improvement and Corrective Action Verification

• Analyse defect data to identify recurring quality issues and trends.
• Verify process parameters and control points associated with identified failure modes.
• Conduct follow-up verification activities to confirm the effectiveness of corrective actions.
• Implement mistake-proofing solutions (Poka-Yoke) where applicable.
• Track corrective action implementation, effectiveness, and closure.

6. Quality Data Analysis and Reporting

• Maintain outgoing quality performance dashboards and defect Pareto charts.
• Monitor customer PPM, internal PPM, scrap, rework, and product failure trends.
• Prepare management reports and escalate critical quality issues to the relevant stakeholders.

Special Skill / Knowledge required:

• 8D /5 Why / Fishbone / FTA

• IATF 16949 & Automotive CSR

• PFMEA / Control Plan / SPC / MSA

• PPAP / APQP

• Root Cause & Failure Analysis

• Dimensional & Functional Inspection

• Customer complain management

• Problem-solving / CAPA

• Poka-Yoke / Lean / Six Sigma

• Automotive plastic injection / moulding knowledge is an advantage.