Foam Quality Control Manager

Position Summary

The Quality Control Manager will help establish and strengthen the company’s quality system for the foam manufacturing operation while providing hands-on leadership on the production floor. This position will work closely with Production, Engineering, Purchasing, and Management to ensure products meet customer specifications, identify and resolve quality issues, and develop processes that prevent problems from recurring.

Primary Responsibilities

• Help develop, implement, and maintain the department’s quality control system, procedures, work instructions, and inspection standards.
• Provide hands-on quality leadership and support on the production floor.
• Establish inspection plans and sampling procedures to ensure foam products meet customer specifications, drawings, tolerances, and quality requirements.
• Oversee incoming material inspection and work with Purchasing and suppliers to address material quality issues.
• Oversee in-process and final inspection activities to ensure product quality and consistency.
• Identify quality issues, investigate root causes, and implement effective corrective actions.
• Manage nonconforming material, including identification, segregation, documentation, and disposition.
• Lead and follow up on corrective actions to ensure issues are fully resolved and do not recur.
• Conduct or support internal quality audits and maintain appropriate quality documentation and inspection records.
• Monitor and report quality metrics, including defects, scrap, rework, customer complaints, and corrective-action closure.
• Work closely with Production and Engineering to identify process variation, improve manufacturing processes, and reduce quality-related costs.
• Support the investigation and resolution of customer quality concerns and prepare corrective-action responses when needed.
• Ensure measuring and testing equipment is properly maintained and calibrated
• Train and develop QC personnel on inspection methods, specifications, procedures, and quality expectations.
• Establish accountability and promote a culture of quality throughout the manufacturing operation.
• Participate in continuous improvement initiatives focused on reducing defects, scrap, rework, customer returns, and cost of poor quality. 
• Perform other duties as assigned.

Skills & Abilities

• Accuracy and attention to detail
• Strong knowledge of quality systems and ISO 9001 principles.
• Strong root-cause analysis and corrective-action skills.
• Ability to conduct or support internal audits.
• Ability to read and interpret engineering drawings, specifications, and tolerances.
• Ability to exercise sound independent judgment and make decisions regarding quality issues, corrective actions, and product disposition. 
• Ability to prioritize multiple quality issues and effectively manage competing deadlines in a fast-paced manufacturing environment.
• Strong problem-solving and analytical skills.
• Ability to identify trends and use quality data to drive improvements.
• Strong communication skills and ability to work effectively with Production, Engineering, Purchasing, and Management.
• Ability to lead, coach, and hold others accountable for quality standards.
• Strong organizational skills and attention to detail.
• Comfortable working hands-on in a manufacturing environment.
• Proficiency with Microsoft Office, particularly Excel.

Education & Qualifications

• Bachelor’s degree in Quality, Engineering, Manufacturing, or a related field preferred; equivalent manufacturing experience may be considered.
• 5+ years of quality control/quality assurance experience in a manufacturing environment.
• Previous leadership or supervisory experience preferred.
• Experience developing, implementing, or maintaining a quality management system.
• Experience with ISO 9001 quality systems required; internal auditor or lead auditor training preferred.
• Experience reading engineering drawings, specifications, and tolerances.
• Experience with quality inspection and measurement equipment such as calipers, micrometers, gauges, scales, and similar tools.
• Experience in foam, plastics, rubber, automotive components, or a similar manufacturing environment is strongly preferred.