Process Quality Engineer - Automotive (EV)
Company Summary: Aspen Aerogels is a rapidly growing aerogel technology company founded in 2001 to capitalize on patented advances in aerogel manufacturing. Aspen has developed a broad portfolio of proprietary aerogel products manufactured at scale and sold worldwide in the Electric Vehicle / Automotive, Energy Infrastructure, Sustainable Building Materials, and Power Generation industries. Aspen is both a Tier 1/2 Automotive supplier, and our Pyrogel™ and Cryogel™ products are used by virtually all leading petrochemical and refining company across more than 50 countries. We’re on a mission to build a world-class organization as we continue to grow our energy infrastructure business, and expand to meet demand in the rapidly growing Electric Vehicle sector over the next 3-5 years. We’re looking for great talent to join our team.
Role Summary: Aspen is looking for an engaging, motivated, and inspirational Quality Engineer to drive Aspen’s quality culture forward in automotive assembly business. The Quality Engineer will report to the Quality Manager – EV Assembly. The Quality Engineer will tackle problem solving on key quality issues across the business’s automotive assembly production lines. The Process QE will also develop and grow the QMS in line with the industry standards (including IATF 16949 and ISO9001: 2015) accreditation requirements & business requirements across the organization through existing & new procedures. The QE will also manage the audit program to ensure that all nonconformities raised against certification bodies during audits are effectively corrected and independently verified. In addition, the Process QE will support a culture of continuous improvement throughout the company in alignment with Aspen’s vision. . The right individual will be an on-the floor leader who establishes efficient, frequent, and collaborative communication with Operations, Process Engineering, and other functions to drive improvements in product quality.
Duties and Responsibilities:
· Be the quality subject matter expert for a group of products in manufacturing. For said product line(s):
o Lead product qualification framework and trialing, including leading the PPAP process.
o Create Control Plans and Work Instructions to support the scale-up process
o Implement new measurement methods and systems for Quality Control
o Drive improvements and solve problems occurring at in-process QC and on the assembly line.
o Be responsible for the daily ownership and reporting of yield and scrap performance for the product line.
o Support daily shop floor meetings on operational performance as needed to support operations.
· Use key product/process metrics to evaluate process effectiveness, identify improvement opportunities/best practices, and drive continuous quality improvement activities.
· Perform analysis of reports and production data to identify trends and recommend updates or changes to quality standards and procedures when necessary.
· Provide support to Operations including the review and approval of manufacturing work instructions, deviation requests, and nonconforming material reports, and Engineering Change Orders.
· Review, approve and develop (as needed) product verification plans and respective test methods.
· Support validation efforts of approved testing to assure compliance.
· Provide validation support by applying manufacturing quality tools including, but not limited to: FMEA, DFMEA, PFMEA, IQ, OQ, PQ, control plans, process verification/validation plans, Cpk, Cp, SPC, DOE, process data analysis, and DMAIC.
· Develop, implement and ensure that Aspen’s Quality Management System conforms to customer, internal, regulatory/legal, and certifying organization requirements.
· Lead or support root cause investigation of nonconformities and develop, initiate, or implement corrective actions using the 8D process.
· Perform employee training on QMS and IATF requirements as needed
· Overall implementation and sustainability of ISO9001 / IATF16949 Certification including any applicable customer specific requirements
· Manages the IATF focused Quality Management System including documentation creation, update, and control - Responsible for activities involving quality control and quality assurance.
· Performs and executes Internal Audits to support the QMS i.e ISO9001 / IATF16949
· Identify gaps and make recommendations to improve effectiveness
· Prepare and provide written and oral reports, communications and/or presentations to management around the development / status of Audits
· Manage customer APQP, CAPA, PPAP, Gage R&R, SPC, as well as other necessary validation work and all automotive quality requirements grounded in IATF 16949.
Qualifications:
· Must have knowledge of Quality Systems requirements. Prefer knowledge of Accreditation Requirements (e.g. ISO 9001 & IATF 16949).
· Must have knowledge of knowledge of sector specific requirements (IATF 16949)
· Lead auditor credentials Required, or must be willing to obtain credentials.
· Excellent communication and interpersonal skills
· Strong organizational skills; attention to detail
· Ability to successfully execute multiple tasks at 1 time
· Good decision-making skills
· Manufacturing experience required
· ISO background
· Experience leading RCI/RCA’s using 5Y, Fishbone, 8D, etc.
· Proven experience in working with suppliers to meet IATF standards
· Has developed measured improvements in scrap $, COPQ, and other key quality KPIs
· Excellent communicator, both up & down the organization
Requirements:
· Minimum of 5 years of experience within an ISO-certified environment in a continuous manufacturing environment preferred.
· IATF knowledge (history of product & site qualification experience) - PPAP expertise
· Prior experience leading teams and/or meetings highly desirable to assist with delivery of and adherence to committed Quality & Operational Excellence goals and development of new programs.
· Bachelor’s degree preferred. Candidates with proven experience in a similar setting will be considered in lieu of degree.
· Adopt and follow Aspen’s core values of Safety, Quality, Integrity, Teamwork, Customer and innovation on both a personal and professional level.
Physical Demands and Work Environment:
· Frequently required to stand
· Occasionally required to walk
· Frequently required to sit
· Frequently required to utilize hand and finger dexterity
· Occasionally required to climb, balance, bend, stoop, kneel or crawl
· Continually required to talk or hear
· Frequently works near moving mechanical parts
· Frequently works around fumes, airborne particles, or toxic chemicals
· Occasionally exposed to extreme heat or cold (non-weather)
· While performing the duties of this job, the noise level in the work environment is usually moderate
· The employee must occasionally lift and/or move more than 10 pounds.
· Specific vision abilities required by this job include: Close vision; Distance vision; Color vision; Peripheral vision; Depth perception and ability to adjust focus