Sr Weld Quality Engineer

Job Summary

This position will lead, execute, and manage Weld Quality Engineering activities across all welding production plants/areas at Stoughton Trailers. This position must act as a primary point of contact, demonstrate strong technical proficiency skills in weld manufacturing process, subject matter expertise in contributing welding technical knowledge and process guidance for all welded components and finished assemblies. Responsibilities include directing, managing Weld School, weld tech, weld quality inspection staff, weld Critical Road Safety (CRS) program, monitoring product weld quality inspection activities on-line, end of line and off-line, adherence to quality systems in the weld areas/processes, including non-conforming material, corrective actions, and calibration. In addition, this position will collaborate with cross-functional areas to provide direction, management and oversight on Quality planning for weld controls and establish quality and compliance standards. Analyze inspection results and assist in problem solving, monitor production parts, prepare inspection plans and instructions, select sampling plan applications, prepare procedures, train weld quality inspectors, perform audits, and apply fundamental statistical methods for process control. Collaborates with engineering, supply chain, manufacturing, operations, quality, suppliers, and/or other functional areas on welding process improvement, quality problem resolution and implementation of effective corrective/preventive actions.

Essential Duties and Responsibilities

• Responsible for adherence to the Cardinal Rules of Safety.
• Lead, execute, sustain weld quality inspection of welded components, sub-assemblies and finished welded parts on-line, end of line and off-line to ensure compliance and conformance to engineering specifications, blueprint dimensions, material and quality standards.
• Monitor, track, analyze weld product quality inspection results/data to assure conformance to weld engineering specifications, customer requirements, and industry welding standards.
• Implement processes as applicable consistent and compliant with AWS D1.1 weld procedure specification, weld performance qualification specified standards while managing welding procedure qualifications and generating welding standard work procedures.
• Assist in conducting failure analysis and root cause analysis on welding quality issues.
• Direct, supervise, manage Weld School functions/staff, weld student training, testing, qualification, ongoing welder performance qualification testing and records.
• Monitor, enforce adherence to Critical Road Safety (CRS) tasks, including effective weld audits.
• Execute, control, analyze and improve tasks related to First Article Inspection (FAI), First Piece Inspection (FPI), layered process audits (LPA) and welded part sampling inspection/audits.
• Develop, refine, track, adjust GMAW weld parameter settings and ranges for wire feed speed, voltage, current, gas flow rate, travel speed including technique and other protocols.
• Provide technical expertise in the area of heat distortion and weld process control methods.
• Resolve distortion problems in production associated to welding with regard to application of heat.
• Recommend and implement new and improved welding technologies and practices, while implementing distortion control methods, providing assemblies with minimal distortion.
• Provide input for training welders to control heat input during production.
• Provide guidance in fixture design to incorporate distortion control methods/techniques.
• Evaluate welding processes and workmanship to ensure compliance with quality requirements, while providing best practices to minimize camber, shrinkage, and distortion due to fixturing and weld process including control on weld spatter and other weld imperfections.
• Interpret engineering drawings and apply requirements in weld inspection activities, select and use measurement gages to verify weld quality characteristics, and evaluate results to determine conformance to specifications.
• Actively participate in new product launch, pilot builds, weld defects/integrity analysis, weld joint discontinuities evaluation/assessment.
• Lead, execute APQP tasks for welding operations i.e. PFD, PFMEA, Control Plans, SPC, AIAG CQI welding system assessment, layered process audits (LPA).
• Support deployment of poka-yoke/mistake-proofing jigs & fixtures/clamps in welding, go/no go and functional gaging methods.
• Assist sorting, inspection, containment, and segregation of non-conforming material while facilitating problem containment at the source and speed to resolution.
• Assist in resolving issues with welding equipment, cutting processes in sheet metal.
• Effectively collaborate and communicate with cross-functional areas in a dynamic fast-paced team environment to achieve superior project goals.
• Seeks feedback and self-assessment to identify stakeholder needs to determine areas of improvement and seeks support in identifying opportunities to professionally grow and enable career advancement.

Qualifications

• Education:
  
  
  
  • Bachelor's degree in Engineering, Welding Engineer, Weld Quality education with minimum 10+ years of quality assurance experience in welding operations, manufacturing, and/or assembly, Business Management degree a plus.
  
  
  
  
• Licenses/Certifications:
  
  
  
  • Welding Engineer or Inspector certification i.e. CWI certification, AWS.
  • Professional certifications i.e. ASQ certifications such as CQE, Six Sigma highly desired.
  • ISO 9001 or IATF Internal Auditor experience preferred.
  
  
  
  
• Knowledge, Skills & Abilities:
  
  
  
  • Demonstrated understanding, fundamental working knowledge and experience in welding, manual and robotic weld operations.
  • Extensive knowledge of physics, engineering, metallurgy, materials, welding, and standards to examine and evaluate welds as well as to plan, supervise, and document welding operations.
  • Experience in ISO 9001, IATF 16949 requirements.
  • Ability to lead, execute and influence stakeholders on decisions related to best manufacturing practices in welding, finished weld quality, results, capabilities, inspection, methods, technique without direct authority.
  • Strong experience in leading / managing projects with demonstration of welding technical expertise.
  • Strong understanding and demonstrated use of quality tools and principles such as 6-Sigma, APQP, PPAP, FMEA, SPC.
  • Strong technical problem solving skills, including root cause analysis with demonstrated use of personal technical competency.
  • Proven success in the use of and mentoring of problem solving methods and statistical decision-making process.
  • Strong analytical skills with the ability to thoroughly analyze, interpret data / information to make sound informed decisions.
  • Experience in project management which may include planning, supervising, monitoring, and accomplishing the goals of specific project requirements.
  • Knowledge of QMS assessment, measurement techniques, and the product development process.
  • Ability to work with all levels of the organization in a team-based environment.
  • Substantial experience in successfully leading teams and the ability to foster key stakeholder relationships.
  • Strong attention to detail and accuracy.
  • Demonstrates the ability to identify self-development needs and explores new opportunities for skill development and professional growth.
  • Quality/Engineering certification is highly preferred, other professional society / organization certification is a plus.
  • Proficient in PC operations including systems and software.
  • Strong organizational and communication skills.
  • Able to travel when required (~10-15%).
  
  
  
  
• Core Competencies:
  
  
  
  • Knowledge of industry standards/guides, accreditation/registration boards in relation to welding.
  • Demonstrated problem solving aptitude, strong foundation and knowledge in FAI, ISIR, and blueprint reading with experience in the interpretation of welding symbols, GD&T scheme on drawings.
  • Experience with CAD software, SolidWorks experience preferred.
  • Strong understanding of fundamental concepts in applied mathematics, statistics, and sampling plans.
  • Prior experience in product and process audit in an assembly / manufacturing environment.
  • Ability to simplify, clarify and intensify execution of actions with the goal of getting things done inside established milestones/timelines.
  • Persistent and tenacious in follow up and follow through to track, monitor and close out issues taking all to the finish line.
  • Move with a high sense of urgency, bias for action, drive for results, possess analytical and critical thinking skills.
  • Self-motivated, confident, energetic, proactive, anticipatory and forward thinking.
  • Ability to use quality data/information/facts to speak up with conviction, articulate findings, assumptions, recommendations and solutions.
  • Well organized, self-starter and a team player both as a member and leader.
  • Ability to multi-task and prioritize work assignments.
  • Good oral and written communication skills, interpersonal behavioral skills.
  • Proficient in computer skills including systems, software, and other database applications.