Job Description
Description:
Location: In-person, Lawrence, MA
This role is responsible for driving quality processes and practices throughout the entire product lifecycle, from initial design to end-of-life. The Senior Manager will collaborate closely with Manufacturing Operations, Engineering, and parts suppliers to ensure the delivery of robust products that meet Bigbelly's objectives for manufacturability, cost, quality, and on-time delivery. The ideal candidate will possess a strong track record in the Manufacturing of electromechanical systems and PCBAs.
- Quality Assurance in Manufacturing: Verify proper specification and inspection of components and finished goods. Ensure manufacturing processes are well-designed, analyzed, and validated.
- Supplier Quality Management: Evaluate component and sub-assembly subcontractors to guarantee hardware quality and adherence to relevant standards and regulations.
- Process and Quality Planning: Partner with the Plant Manager to develop, implement, and maintain essential documentation such as Process Flows, Control Plans, Measurement System Analyses (MSAs), and Quality Plans.
- Inspection and Testing: Establish and implement effective inspections, test methodologies, and sampling plans to confirm that supplier parts and assembled product s meet specifications and expectations.
- Technical Expertise: Provide technical guidance in conducting Process Failure Mode and Effects Analyses (PFMEAs) with Suppliers and in developing process validations.
- Supplier Change Management: Ensure proper approval, documentation, and communication of Supplier Change Requests.
- Problem Solving and Failure Analysis: Support quality metrics and provide leadership in resolving issues and conduct failure analysis with manufacturing partners and component suppliers.
- Design for Manufacturability (DFM): Support DFM initiatives both within Bigbelly and with manufacturing partners.
- Mechanical Design Support: Offer guidance and support to the mechanical design team to facilitate successful new design introductions at mechanical fabrication vendors, including First Article Inspection and First Off Tool Sample approval.
- Root Cause Analysis and Corrective Actions: Conduct thorough root cause investigations for product quality issues and implement appropriate corrective and preventive actions. Investigate and report on field quality issues and product failures, leading cross-functional resolution efforts.
- Reliability Monitoring: Calculate and monitor the Mean Time Between Failures (MTBF) of designed products and recommend improvements to enhance reliability.
- ISO Certifications: Conduct timely audits of our ISO 9001 and ISO 14001 for compliance as well as process improvement.
Requirements:
Required:
- Bachelor's or master’s degree in industrial engineering, Mechanical Engineering, or a related technical field with a strong background in electromechanical and electronics assembly .
- Minimum of 7 years’ experience as a quality manager overseeing quality control, developing and implementing quality systems, and ensuring compliance with regulations and customer requirements.
- Minimum of 10 years of experience in Quality Assurance/Quality Engineering roles focused on Manufacturing assembly operations. Broad knowledge of mechanical/plastics parts manufacturing is desired.
- Proven experience in transitioning products from the design phase into manufacturing.
- Solid engineering knowledge in FMEA, Statistical Process Control (SPC), Process Characterization, and Gage Repeatability and Reproducibility (GR&R).
- Familiarity with IPC610 guidelines and ISO standards.
- Strong foundation in Manufacturing Engineering, Design for Manufacturability, and New Product Introduction processes.
- Proficiency in utilizing analytical tools and methods, including statistics (Minitab preferred), Design of Experiments (DOE), and relevant computer software for design, development, and manufacturing.
- Highly self-motivated with a demonstrated ability to lead teams effectively without direct authority.
- Willingness and ability to travel approximately 15–30% of the time for supplier visits or business meetings, both domestically and internationally.
Preferred Additional Skills and Qualifications:
- Experience working with Tier 1 and 2 EMS or CM providers.
- Knowledge of Lean Manufacturing principles.
- Six Sigma Black Belt certification.
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