Manufacturing / Program Quality Engineer

Manufacturing / Program Quality Engineer

Location : Racine, WI

Duration : Permanent

Job Summary

The Manufacturing / Program Quality Engineer is responsible for ensuring product and process quality throughout the product lifecycle—from APQP and NPI/NCI execution through launch, validation, and sustained production. This role partners cross‑functionally with Engineering, Manufacturing, Supply Chain, and Suppliers to manage risk, validate processes, drive problem resolution, and deliver continuous improvement aligned with quality and business objectives.

Key Responsibilities

APQP & Program Execution

• Lead and support APQP, NPI, and NCI activities, ensuring alignment with phase‑gate requirements and program milestones.
• Participate in and support Phase Gate Reviews, assessing quality readiness and risk prior to launch.
• Drive Launch Readiness activities to ensure robust processes and product quality at start‑of‑production.

Risk Management

• Develop and maintain PFMEAs, identifying, prioritizing, and mitigating process and product risks.
• Capture and deploy Lessons Learned across programs to prevent recurrence and improve future execution.
• Proactively identify emerging risks and implement mitigation actions in collaboration with cross‑functional teams.

Process Control & Standardization

• Create and maintain Control Plans, Process Flow Diagrams, and Standard Work documentation.
• Implement Error Proofing (Poka‑Yoke) solutions to prevent defects at the source.
• Ensure process controls are effectively cascaded to manufacturing and suppliers.

Validation & Capability

• Lead or support IQ/OQ/PQ, Run‑at‑Rate, and process validation activities.
• Perform and interpret Cp/Cpk studies and MSA (Gage R&R) to confirm process capability and measurement system integrity.
• Ensure validated processes meet quality, capacity, and customer requirements.

Problem Solving & Corrective Action

• Lead structured problem‑solving using 8D, 5 Whys, Fishbone, and CAPA methodologies.
• Drive root‑cause identification, corrective and preventive actions, and effectiveness validation.
• Collaborate with internal teams and suppliers to resolve quality issues quickly and sustainably.

Manufacturing Quality

• Define and optimize inspection strategies, including FAI, in‑process checks, and final inspection.
• Monitor and analyze SPC data to detect trends, prevent escapes, and drive process stability.
• Support audits and ensure compliance with internal QMS and external standards.

Continuous Improvement

• Apply Lean and Six Sigma (Green Belt) methodologies to reduce defects, variation, and waste.
• Lead or contribute to continuous improvement initiatives that improve quality, cost, and delivery.

Tools & Systems

• Utilize quality and data analysis tools such as Minitab and MS Excel for statistical analysis and reporting.
• Work within PLM, ERP, and QMS systems to manage quality records, changes, and documentation.

Qualifications

Required:

• Bachelor’s degree in Engineering or related field.
• Experience in APQP, manufacturing quality, or program quality engineering.
• Working knowledge of PFMEA, Control Plans, SPC, MSA, Cp/Cpk, and structured problem‑solving.
• Proficiency with Minitab, Excel, and enterprise systems (PLM/ERP/QMS).

Preferred:

• Six Sigma Green Belt certification.
• Experience supporting NPI/NCI launches in a manufacturing environment.
• Strong cross‑functional collaboration and communication skills.

“Tekshapers is an equal opportunity employer and will consider all applications without regards to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.”