Quality / Manufacturing Engineer — Gear Manufacturing Commodity SME
sqaservices · Cicero, IL · hybrid
USD 65 to 75 · period not stated
Key Responsibilities:
- ▪ Lead the on-site assessment as the gear manufacturing commodity SME, including the opening meeting, daily out-briefs, and closing meeting with the supplier and client.
- ▪ Facilitate the Requirements Consumption Review (RCR) with the supplier’s cross-functional team and client (virtual), covering contract review, product definition, build plan, inspection and test, CAPA, general workmanship, and tooling / property management.
- ▪ Walk the gear manufacturing process flow step by step — blank preparation, worm thread generation, wheel hobbing, heat treatment, grinding and finishing, inspection, and shipment — identifying credible failure mechanisms and evaluating the prevention and detection controls in place (reverse-PFMEA approach).
- ▪ Evaluate controls specific to multi-start worm gearing, including lead, pitch and index accuracy, hob and special-tooling condition, heat-treat distortion, case depth and hardness, grind burn, contact pattern, backlash, and center distance.
- ▪ Evaluate QMS effectiveness as applied to the part, including MRB, nonconformance handling, corrective action, traceability, sub-tier special-process flow-down, and continuous improvement.
- ▪ Where PPAP is required, assess the supplier’s readiness to execute a compliant PPAP: APQP planning, process flow, PFMEA, control plan, capability studies, and submission process.
- ▪ Evaluate special-tooling readiness, capacity, and schedule feasibility against the quoted lead time and identify risks to on-time delivery.
- Consolidate findings with the Technical Lead into a gap register, rating each gap by risk and state of control, and recommend actions for the client and supplier.
- ▪ Author the Supplier Readiness Assessment Report for SQA technical review within the required timeline and support the client readout.
Required Qualifications:
- ▪ Bachelor’s degree in mechanical, manufacturing, or industrial engineering, or an equivalent combination of education and at least 10 years of directly related experience.
- ▪ Minimum 7 years of hands-on quality or manufacturing engineering experience in precision gear manufacturing, including worm gear or worm-thread production.
- ▪ Demonstrated working knowledge of gear cutting and finishing processes (hobbing, worm milling or thread grinding, gear grinding) and of gear heat treatment (carburizing, induction hardening, or nitriding).
- ▪ Working knowledge of AGMA gear quality standards and of gear inspection methods and results (lead, profile, pitch, runout, single- / double-flank testing, contact pattern).
- ▪ Hands-on experience developing or reviewing PFMEAs and control plans, and executing or reviewing PPAP / APQP per AIAG requirements.
- ▪ Prior experience leading supplier audits or assessments, with lead auditor training or certification to ISO 9001 or AS9100.
- ▪ Ability to read and interpret engineering drawings, gear data tables, and GD&T per ASME Y14.5.
- ▪ Strong technical writing skills; able to produce clear, evidence-based reports on deadline.
- ▪ Able to travel to and work on site at the supplier facility for the full two-day assessment, including shop-floor access with required PPE.