Quality Engineer - Product

We are currently seeking a highly motivated Quality Engineer to join our fast-paced, dynamic team and support FCE's business plan by effectively and proactively ensuring the highest possible quality levels of our power plant products and the site construction/installation of our projects. The ideal candidate must be well versed in quality engineering processes such as quality planning, process and product qualification, development, integration, monitoring, auditing, corrective/preventative action, and continuous improvement. In addition, this individual must have the ability to work with all levels of the organization as a cross-functional team member.

Responsibilities

The Quality Engineer is responsible for proactively ensuring the quality of all aspects of the balance of plant for FuelCell Energy Block Systems and the quality levels for incoming purchased materials and services supporting our fuel cell projects.

• Provides Quality interface and expertise within the Danbury Headquarters and with the Engineering groups to proactively assure that product requirements are well developed, understood, and satisfied.
• Defines Supplier Qualification processes, required levels of process capability, and process controls to ensure that Cost of Quality goals are achieved.
• Works with suppliers to develop and approve Inspection and Test Plans (ITPs) for equipment, components, engineered systems and contract manufactured skid systems.
• Verifies supplier data, inspection and NDE reports, FAT reports, and completion of all Mechanical and Electrical system inspections, checkouts, and tests. Performs walk downs for all appropriate equipment/systems to assure all quality requirements of ITP have been met.
• Performs inspections for proper Installation, Wiring, Termination and Insulation Testing, Hi potential cable Testing, cold loop checking, earth continuity resistance test, low ohm test for bus bars, leak testing, and pre-commissioning of equipment.
• Drives Supplier Quality via conducting supplier surveys, on-site audits, and follow up audits, to qualify and assess supplier's quality and manufacturing capabilities. Support the supplier qualification process, surveillance program and supplier development programs.
• Drives site construction and product installation Quality at project sites. Performs proactive QA/QC inspection to the ongoing construction activities to align/comply with all construction tasks to the project procedures, standards, and specifications and ensure that it follows all relevant approvals.
• Participates in the Design and Product Development Process to connect product Critical to Quality (CTQ) requirements with process requirements and ensuring successful execution of related Verification and Validation plans.
• Qualifies, controls, monitors, and continuously improves internal and external (supplier) processes using Lean Six Sigma tools.
• Executes Nonconformance Report activities and assists with creating/maintaining Corrective Action entries within ERP system to address supplier related issues.
• Leads and participates in investigations, root cause analyses, and corrective/preventive action solutions as needed using Lean Six Sigma tools applied in an 8D framework.
• Supports the continuous improvement of FCE's Quality Management System (QMS) processes and related documentation.
• Develops, executes and analyzes quality-reporting measures and periodically reports to management on quality issues, supplier performance, non-conformances, corrective actions, trends and losses, always with a plan included for resolution and/or improvement.
• Performs Internal Audits in accordance with ISO-9001 and internal requirements.

Qualifications

Education: B.S. degree in Mechanical, or Electrical, Chemical, or other related engineering degree required.

Experience: 5+ years of relevant experience in Quality Engineering required.

Candidate Must Have:

• Six Sigma Green Belt or higher; or demonstrated application of statistical concepts (e.g. Lean Six Sigma tool application and Reliability Engineering).
• Demonstrated use of Lean Six Sigma tools to manufacturing/supplier process qualification, control, root cause & corrective action, and continuous improvement. E.g. MSA, DoE, SPC, FMEA, 5 Whys, etc.
• Experience in the following equipment and manufacturing categories: Engineered Equipment and Skid Assembly, ASME B31.3 Welding; ASME Pressure Vessel Fabrication; Heat Exchangers, Gas Compressors. Battery And UPS Systems, VFD's, Power Distribution Systems, Low, Medium, And High Voltage Switchgear and MCC's, Motors and Motor Controls, Transformers, PLC Control Systems. Instrument & Controls and Electrical Wiring Checkout; Structural Steel and Sheet Metal Fabrication; Welded Fabrications; Skid Manufacturing Quality and Site Construction Quality.
• Detail-oriented and methodical mindset.
• Must have knowledge of inspection methods and techniques.
• Experience utilizing standard mechanical, chemical and electrical measurement instruments and functional gauges.
• Ability to read and interpret technical drawings and product requirements.
• Strong technical writing and communication skills.
• Demonstrable ability to work effectively both as a team member and independently.
• Cross functional team leadership skills.
• Excellent computer skills, specifically Microsoft Office Suite.
• Knowledge of ISO9001 standard, quality systems, policies and procedures preferred.
• Experience with ERP and database system use preferred. Experience with Microsoft Dynamics 365/ERP Solutions Quality software a plus.
• Hands-on experience operating multimeters and process meters to complete I/O loop checks and troubleshooting a plus.

Physical Requirements / Working Conditions

• Domestic and International Travel required: up to 70%.
• Able to travel between CT locations regularly.
• Ability to obtain/maintain a valid passport and travel without restriction internationally is required.
• Must be able to work physically in the manufacturing plant or construction site, wearing required personal protective equipment (PPE) such as safety gloves, hard hats, safety shoes, etc., as designated.
• Lifting up to 25 pounds, walking (standing) in a large manufacturing plant, on concrete flooring or uneven installation/construction site for extended periods of time.
• Periodic bending, reaching - working with both hands and arms in full range of motion; and climbing ladders required to perform inspection of incoming, installed, or manufactured parts.
• Ability to hear or be aware of audible danger alerts.
• Ability to remain on feet and move from area to area within a supplier shop or construction site.
• Computer work for extended periods of time is also required.
• Ability to distinguish color.