Senior Quality Engineer (Sofa Manufacturing)

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JOB SUMMARY:
Lead and oversee quality assurance initiatives to ensure the company's products meet established quality standards and continuously improve performance. Drive continuous improvement across production processes and product quality by leading technical teams and implementing advanced QA methodologies. Develop and execute comprehensive quality strategies, manage customer quality performance, and mentor Quality Engineers. Collaborate with cross-functional departments to establish quality culture and ensure regulatory compliance.
Establish, implement, monitor, and continuously improve the Failure Mode and Effects Analysis (FMEA) process to ensure early identification and mitigation of risks related to design, raw materials, manufacturing processes, and Critical Control Points prior to releasing new items for mass production.
ESSENTIAL DUTIES & RESPONSIBILITIES:
Lead and mentor Quality Engineers, providing technical guidance, training, and support to strengthen quality capabilities and ensure compliance with quality standards.
Review and approve quality inspection plans, procedures, checklists, and SOPs to ensure consistency and compliance with company requirements.
Lead quality analysis for new products and manufacturing processes, identifying potential risks and implementing preventive measures before mass production.
Develop and standardize the FMEA process within the New Product Introduction (New GO) workflow, covering four key risk areas: Material, Design, Process, and Critical Control Points.
Lead FMEA risk assessments for New GO items from PP sample development through Pilot Run, including post-trial reviews and Kit Auditing before Wanek FO Review.
Maintain and update the Critical Points Master-list, documenting identified risks, assigning corrective actions, and tracking completion against deadlines.
Monitor quality performance, defect trends, customer complaints, and KPIs. Lead Root Cause Analysis and ensure effective implementation of Corrective and Preventive Actions (CAPA).
Analyze Pass/Fail/Transit rates by SKU and collaborate with cross-functional teams to determine appropriate product changes and risk mitigation actions.
Support initial production runs by investigating quality issues, identifying root causes, and implementing timely corrective actions to prevent recurrence.
Work closely with the U.S. Team and cross-functional departments, including Coverfit, Sample Development, Cutting, Sewing, OBQ, QC/QA, and Packaging, to ensure end-to-end product quality.
Drive continuous improvement initiatives to reduce defects, strengthen process control, and improve product quality throughout the production lifecycle.
Monitor key quality KPIs, including on-time FMEA completion, defect reduction, corrective action compliance, and Critical Points Master-list accuracy.