Senior Quality Assurance Engineer in Bridgwater

Senior Quality Engineer Overview The Senior Quality Engineer plays a central role in driving shop-floor quality, proactive risk mitigation, and systematic continuous improvement across our precision electro-mechanical assembly operations. Working closely with senior quality leadership, this role champions a preventive quality culture, using data-driven methodologies to eliminate manufacturing vulnerabilities, reduce scrap, and optimize assembly efficiency. This role operates on a structured, mentored succession pathway with the explicit objective of stepping into the Quality Manager role within 2 to 3 years. Key Responsibilities & Deliverables * Assembly Quality, Defect Prevention & Continual Improvement: * Manage daily shop-floor quality gates, rework dispositions, scrap logging, and concession reviews within the MES (eBoss). * Champion site Continual Improvement (CI) action plans by analysing scrap trends, first-pass yield, and assembly bottleneck data to drive targeted Kaizen and Lean/Six Sigma defect-reduction projects. * Lead containment and root cause investigations using structured 8D, Ishikawa, and 5-Why problem-solving tools, ensuring corrective and preventive actions (CAPA) permanently eliminate failure modes. * Update and optimize workstation Control Plans, Standard Operating Procedures (SOPs), operator training matrices, and tool calibration schedules. * Proactive Risk Management & Change Control: * Champion risk management methodologies on the assembly line, creating and maintaining Process Failure Mode and Effects Analysis (PFMEA) to anticipate build risks and implement mistake-proofing (Poka-Yoke) solutions. * Evaluate Engineering Change Notices (ECNs) through a risk-based lens, assessing impacts on product reliability, tooling, test protocols, and quality documentation prior to sign-off. * Conduct routine shop-floor Health, Safety & Environmental Risk Assessments (~2 per month) and maintain operational risk registers. * Supplier Quality Risk & Incoming Assurance: * Mitigate supply chain quality risks by validating Initial Sample Inspection Reports (ISIR), Part Submission Warrants (PPAP), and Supplier Control Specification Sheets (SCSS), including Gauge R&R / MSA and Cpk capability verification. * Manage Goods Inwards inspection standards, raise supplier rejections in WinMan ERP, and partner with procurement to enforce robust Supplier Corrective Action Requests (SCAR). * Participate in risk-based supplier onboarding audits (~6 per annum) and supplier technical audits (~3 per annum, including domestic and international travel). * Customer Assurance & QMS Governance: * Manage customer warranty investigations (~2 per month), leading root cause teardowns and delivering comprehensive 8D reports that demonstrate verified systemic prevention. * Support external certification and customer audits, conduct risk-based internal audits across ISO 9001 / ISO 14001, and coach internal auditors in identifying systemic non-conformances and improvement opportunities. Succession & Progression Milestones * Year 1: Full operational autonomy over daily concessions, ERP/MES transactions, calibration, 8D warranty closures, and ownership of the monthly CI action register. * Year 2: Lead internal auditing programs, direct supplier risk assessments, manage PFMEAs, and deliver monthly Quality & CI KPI reporting to management. * Year 3: Lead external ISO recertifications, chair Management Reviews, direct the business risk register, and formally step into the Quality Manager role. Candidate Specification & Qualifications * Experience: 5+ years in Quality Engineering within precision electro-mechanical assembly, precision mechanical manufacturing, or automotive tier-1 environments. * Competencies in Risk & CI: * Proven track record in applying Risk Management tools (PFMEA, risk assessments, mistake-proofing). * Strong practitioner of Continual Improvement tools (8D, DMAIC, 5-Why, Value Stream Mapping, SPC, Cpk). * Practical application of Core Tools (APQP, PPAP, MSA, FMEA, SPC). * ISO9001 / ISO14001 Internal Auditor (Ideally Lead Auditor status) * Standards & Systems: Working knowledge of ISO 9001:2015 and ISO 14001:2015 (Internal Auditor qualified); experience with ERP (e.g., WinMan) and digital MES software (e.g., eBoss). * Education: HNC/HND or BEng in Mechanical, Electrical, or Manufacturing Engineering (or equivalent demonstrable industry experience)