Resident Engineer

Tuscaloosa, Alabama

Post Date: 08/15/2016 Job ID: 6242 Industry: Other Area(s)


Bachelor Degree in engineering

5 to 10 years’ experience as quality engineer, resident engineer, supplier quality engineer


  • Develop and establish a close and strong relationship with customer key contacts
  • Initiate preliminary investigation of suspect products reported at customer location or at the sorting company
  • Keep track of all customer complains disputed/voided (Quality Concerns tracking FORMAT rev 1.0 Sep 15 2014)
  • Prepare initial customer complain report using “ Failure analysis checklist” (QAPF-013-002- Failure Analysis Checklist rev 03-June 18 2015), including pictures of concern and A-B-A results and communicate to all organizations involved (Manufacturing, Quality, Design, etc.). Distribution list to be defined along with site Quality coordinator and site Quality manager
  • Ships back suspect product(s) to the manufacturing plant or any other location for root cause investigation. Samples must be ship back via overnight so parts arrive as soon as possible.
  • Initiate, implement and drive containment actions at customer location, this includes training and supervision of inspectors of sort and method criteria, part marking and part tracking. Use as guide the “ Sorting Activities Checklist” (Sorting activity Check list rev 1.0 Sep 15 2014)
  • Establish a clean point at customer location, communicate clean point to all involved organizations including the customer
  • Coordinate the segregation and disposal (scarp, ship back to manufacturing plant and/or rework) of the faulty or suspicious product.
  • Coordinate implementation of clean point with countermeasure/certified parts supplied by manufacturing plant.
  • End inspection activity with customer’ s concurrence.
  • Follow up 8D completion with manufacturing plant, review 8D and provide feedback before final submission to customer.
  • Dispute any discrepancies with customer until quality records reflect accurate results.
  • Monitor quality of this company products at customer site
  • Communicate any potential issues to all organizations involved
  • Implement proactive actions to prevent potential problems from becoming real problems at customer site, this includes any customer activities that may potentially affect the product.
  • Identify areas for improvement to product based on knowledge of customer’ s operation.
  • Coordinate trial runs at customer location
  • Coordinate Yard Campaigns as requested by the customer and approved by the affected this company site quality coordinator and quality manager.
  • Support product launch activities at customer location Support and represent This company at any supplier activities/events required by Customer
  • Escalate issues to either customer or/and upper management following internal escalation process.
  • The resident engineer should publish on a weekly basis an activities report. The report should contain:
  •       a) Pride points (NCT, QR, PRR, successfully disputed/voided)
  •       b) Sorting activities results
  •       c) PPM data for the week
  •       d) Critical Points
  • Dispute and record all cost charges from Customer to the plants



  • Primary customer on-site contact for any product quality related issues
  • Become main channel of communication between customer and This company
  • Confirm failure mode of product using A-B-A process, whenever possible.
  • If customer complain cannot be confirmed with suspect part, dispute customer complain to be removed from the company records.


  • Headlamps manufacturing process
  • Molding Area / Learn about common molding issues
  • Training on inspection standards (Cosmetic specifications), repairs and reworks
  • Control plan, FMEA review
  • Review latest 6 months open-closed 8Ds
  • Assembly area / Repair procedures and lamp troubleshooting
  • FMEA and control plan review
  • Bill of Material / Exploded View:  With the correct component name/terminology and this company’ s part numbers.
  • Line poka yoke and its functionality
  • Assembly area testing procedures / AL Checker use and capabilities 
  • Schematic of Quality Checks - What every mark on the lamp represents?  EOL marks and grease pencil marks (e.g. vent present)
  • Cosmetic Specifications
  • Customer Requirements – Fit and Finish (Gaps and Flush) and Appearance/Cosmetics
  • Customer score card status
  • Resident Engineer formats and procedures


Tammy Turner

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