Toyota Boshoku AKI USA, LLC

Quality Control Specialist

Job Locations US-AL-Athens
ID
2024-1243
Category
Quality Control
Type
Regular Full-Time

Overview

  1. General Summary: To plan, develop, implement quality systems to ensure plant parts meet or exceed customer expectations. Responsible for investigating, analyzing, containing, and correcting quality problems related to final customer products. This position may also perform audits and implement new strategies to improve the condition of plant quality.

Responsibilities

Essential Job Functions:

  1. Change Point Control
    • Work with Production Control to identify new engineering change points (ECI/ECN).
    • Track change points from supplier to TBAKI PC.
    • Work with TBAKI PC to Quarantine new level parts until old level inventory is exhausted.
    • Review supplier quality manual to ensure all customer requirements are met for each change point.
    • Understand any part validation required for each change point at TBAKI and suppliers, check dimensional/performance test results from supplier and coordinate dimensional/performance testing at TBAKI.
    • Verify that all documentation for each change point is complete and communicate to customer per supplier quality manual (customer specified requirements).
    • Work with Tier 1 to communicate change points to customer.
  2. Serve as liaison between plant and its customers/suppliers providing quality related technical assistance in the investigation, containment, and resolution of quality problems.
  3. Coordinate each phase of the quality control/assurance activities of new and existing projects to ensure product quality, schedules, and time frames meet customer requirements.
  4. Collect information and research data related to quality standard requirements to comply with customer requirements.
  5. Analyze and provide input regarding quality of raw materials, purchased parts, and other items required to manufacture automotive interiors parts and components or powetrain.
  6. Review material lists of conformance to company standard practices in regard to parts and materials used.
  7. Analyze processes for improvements, failure modes, stability, and capability.
  8. Coordinate process change requests and Engineering Change Instruction (ECI) implementation related to quality assurance activities including preparing supporting documentation, change point tracking, communications, sample part reviews, and scheduling trial parts.
  9. Ensure that any new inspection equipment for the product/process is approved and maintained in the calibration system.
  10. Work with the Manufacturing department to initiate effective containment, investigation, and countermeasure activities to prevent further outflow in-house and to customer.
  11. Conduct quality audits including performing vehicle (end use applications) evaluations, problem analysis, and providing design/redesign input.
  12. Manage and maintain quality assurance documents including quality assurance plan, tool progress report, evaluation plan, inspection standards, supplier and customer quality standards, Supplier Quality Assurance Manual (SQAM), Quality Assurance Standards (QAS), Process Flow, Process Failure Mode Effects Analysis (PFMEA), Manufacturing Quality Chart/Control Plan (MQC/CP), Initial Sample Inspection Report (ISIR), etc.
  13. Support and assist with planning, development, and implementation of quality systems and activities with suppliers to ensure supplier parts meet or exceed plant and customer expectations.
  14. Oversee and support service part quality issues and warranty claims as necessary.
  15. Assist in developing quality management system (e.g., TS 16949) based procedures and instructions.
  16. Initiate, prepare, and present plans for quality improvements and train required team members.
  17. Complete miscellaneous reporting, administrative, and other quality related functions for the Quality Control department as required including QC Circle participation, Key Performance Indicator (KPI) reporting, quality dojo creation/training, and launch document preparation, etc.

Qualifications

Education:

    • High school diploma, GED, or equivalent required.
    • Associate's or Bachelor’s degree in Engineering, or related field required; or an equivalent combination of education and experience.
    • Additional trade education and Quality certifications are preferred.

 

 Experience:

    • Greater than five (5) years of relevant experience and academic preparation or 10 years of relevant experience.
    • Minimum of two (2) years of industrial inspection experience.
    • 3-5 years of Quality Control experience in a manufacturing facility with progressing level of responsibility preferred. Automotive environment preferred.
    • Quality Control program launch experience for new programs preferred.
    • Experience with manufacturing processes, tooling, quality control methods, and statistical process control (SPC).
    • Experience creating PPAP and Manufacturing Quality Chart (MQC) documents.
    • Experience with Toyota launch systems and requirements preferred.
    • Welding experience for arc, spot, and projection welding is a plus.
    • Injection Plastics and Urethane process experience are a plus.
    • Experience with measurements skill and knowledge or various measuring equipment is a plus.
    • Previous exposure to a multicultural office environment preferred.
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 Personal/Technical Skills:

    • Working knowledge of quality audit techniques.
    • Must be trusted with confidential data.
    • Basic shop math ability required (i.e., addition, subtraction, multiplication, division).
    • Understanding of conceptual math (i.e., basic geometry, charts and graphs) required.
    • General understanding and working knowledge of product design specifications functions and quality standards of finished product as well as parts/materials used.
    • Thorough understanding and working knowledge of automotive plants and processes, company products, trade terminology, quality management and control systems and techniques, manufacturing processes, tooling and equipment, and machine operation.
    • Ability to read, interpret, and understand engineering documents such as automotive drawings (component, assembly, and equipment), technical standards, design specifications, general tolerances, critical characteristics, Geometric Dimensioning and Tolerancing (GD&T), Engineering Change Instructions (ECI), Prototype Parts Requests (PPR), and color instructions.
    • General understanding of the Toyota Supplier Quality Assurance Manual (SQAM) and Toyota Production System (TPS) is preferred.
    • Good understanding of seat, welding, door, carpet, and headliner processes are a plus.
    • Good presentation skills.
    • Effective time management skills.
    • Ability to work in a team environment.
    • Strong organization and planning skills.
    • Excellent critical thinking skills required.
    • Good assertiveness and negotiation skills.
    • Ability to understand inspection standards.
    • Hands-on, self-starter with a strong work ethic.
    • Active listener with effective communication skills.
    • Ability to compile effective and concise visual reports.
    • Ability to perform responsibilities with minimal supervision.
    • Ability to work in a fast-paced, multicultural work environment.
    • Ability to maintain records and files and prepare recaps and reports.
    • Ability to maintain on call flexibility to control abnormal conditions.
    • Ability to be flexible in a constantly changing production environment.
    • Ability to communicate and work well with all levels of the organization.
    • Ability to create excellent working relationships with internal and external customers.
    • Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.
    • Ability to multitask and facilitate effective problem solving and resolution.

 

 Language Skills:

  • Strong verbal and written communication skills in English.
  • Japanese is a plus.

 

Computer/Software:

  • Solid working knowledge and experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Outlook, Internet, Newton, NEC, etc.). AutoCAD experience is desirable.

 

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