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Quality Assurance Manager - 1st Shift

IDEAL Industries

  • Sycamore, IL
  • Today
  • $86,985–$116,995 Per Year

Highlights

Develop and maintain quality dashboards and KPIs (PPM, COPQ, first-pass yield, scrap rate, customer complaint rates, audit scores, etc.) and present actionable insights to plant leadership. The Quality Assurance Manager is responsible for leading, developing, and managing the plant's quality management system (QMS), quality engineering, and quality inspection functions.

Numbers & Facts

LocationSycamore, IL
IndustryElectronics, Components, and Semiconductor Mfg
Salary$86,985–$116,995 Per Year
Company Size2,500 to 4,999 employees
Year Founded1916
Websitehttp://www.idealindustries.com/

Description

IDEAL Industries, Inc. has built a reputation for over a century by crafting iconic tools and practical technology required in aerospace, data communications, electrical, wire processing and construction. The global family of IDEAL brands includes IDEAL Electrical, Anderson Power, and Enatel. A vibrant and dynamic company, IDEAL is best known for our wire connectors, the gold standard for making electrical connections around the world. Nearly every commercial jet is assembled using IDEAL wire strippers and, as part of the critical equipment on NASA missions, our tools even help NASA astronautsfly to the moon. Most important, our products benefit skilled tradespeople, who reach for IDEAL tools every day.

IDEAL is propelled by the concept of Building an IDEAL World. Our family-run business is committed to building ideal relationships with customers, employees, and communities by crafting some of our industry's most innovative and trusted tools.

The Quality Assurance Manager is responsible for leading, developing, and managing the plant's quality management system (QMS), quality engineering, and quality inspection functions. This role ensures that all products - spanning residential and industrial electrical markets - consistently meet or exceed customer expectations, internal standards, and all applicable domestic and international regulatory requirements. The Quality Assurance Manager drives a culture of data-driven decision making, continuous improvement, and operational excellence. This position directly leads a team of Quality Engineers and Quality Technicians and reports to the Plant Manager.

Responsibilities:

Quality Management System (QMS) Leadership
  • Own, maintain, and continuously improve the plant's QMS in compliance with ISO 9001:2015 and lead the transition to ISO 9001:2026 upon publication, including gap analysis, updated documentation, internal audits, and staff training aligned with the new standard's emphasis on quality culture, ethical behavior, and enhanced risk-based thinking.
  • Plan, schedule, and lead internal audits; manage external/third-party certification audits and customer audits. Ensure audit findings are resolved with robust corrective and preventive actions (CAPA).
  • Develop and maintain quality policies, procedures, work instructions, and other controlled documentation in accordance with QMS requirements.


Regulatory & Standards Compliance (Global)
  • Serve as the plant's subject matter expert on UL standards, qualification testing, and the UL approval/listing process for electrical products, including managing UL file reviews, follow-up inspections, and new product submissions.
  • Ensure product compliance with global regulatory and market-specific requirements including, but not limited to:
    • RoHS (Restriction of Hazardous Substances)
    • California Proposition 65
    • CE Marking (EU Low Voltage Directive, EMC Directive, etc.)
    • ASME standards
    • DIN standards
    • REACH, WEEE, and other EU environmental directives
    • CSA, ETL/Intertek, and other NRTL certifications
  • Country-specific regulatory bodies (e.g., CCC for China, PSE for Japan, SAA for Australia, SASO for Saudi Arabia, etc.)
  • Monitor evolving regulatory landscapes across global markets and proactively communicate impacts to engineering, product management, and operations teams.


Data-Driven Quality & Statistical Methods
  • Champion a data-driven decision-making culture across the quality organization and plant floor. All quality decisions, dispositions, and improvement initiatives must be supported by quantitative analysis.
  • Apply and coach the team in the use of statistical quality methods and tools including:
  • Statistical Process Control (SPC) - control charts, process capability indices (Cp, Cpk, Pp, Ppk)
  • Measurement System Analysis (MSA) - Gage R&R studies
  • Design of Experiments (DOE)
  • Hypothesis testing, regression analysis, ANOVA
  • Reliability analysis (Weibull, MTBF, life testing)
  • Acceptance sampling plans (ANSI/ASQ Z1.4, Z1.9, LTPD, AQL)
  • Pareto analysis, cause-and-effect diagrams, FMEA (Process & Design)
  • Develop and maintain quality dashboards and KPIs (PPM, COPQ, first-pass yield, scrap rate, customer complaint rates, audit scores, etc.) and present actionable insights to plant leadership.


Six Sigma & Continuous Improvement
  • Apply Six Sigma methodology (DMAIC/DMADV) to lead and facilitate cross-functional improvement projects that reduce variation, eliminate defects, and improve process capability.
  • Familiarity with Lean Manufacturing principles (5S, Kaizen, value stream mapping, waste reduction) and their integration with quality systems.
  • Drive root cause analysis using structured problem-solving methods (8D, 5-Why, Ishikawa, fault tree analysis).
  • Lead or sponsor continuous improvement initiatives aligned with plant goals and customer requirements.


Inspection, Metrology & Quality Equipment
  • Oversee the selection, calibration, maintenance, and effective use of both legacy and modern quality and inspection equipment including:
  • Coordinate Measuring Machines (CMMs) - contact and non-contact
  • Vision inspection systems (2D/3D automated optical inspection, machine vision cameras)
  • Optical comparators and profile projectors
  • Hardness testers, surface roughness testers
  • Pin gages, thread gages, ring gages, go/no-go fixtures
  • Calipers, micrometers, height gages, dial indicators
  • Electrical test equipment (hi-pot testers, insulation resistance testers, continuity testers)
  • Force/torque measurement devices
  • Manage the calibration program ensuring all measurement and test equipment is traceable to NIST or equivalent national standards and within calibration intervals.
  • Evaluate and implement emerging inspection technologies (e.g., inline automated vision, AI-assisted defect detection) where ROI and quality improvements justify adoption.


Team Leadership & Development
  • Directly manage, mentor, and develop a team of Quality Engineers and Quality Technicians, including performance management, goal setting, training plans, and succession planning.
  • Foster a team culture of accountability, technical curiosity, and continuous professional development.
  • Ensure adequate staffing and skill coverage across shifts and product lines.
  • Conduct regular team meetings, performance reviews, and cross-training initiatives.


Supplier Quality Management
  • Establish and maintain incoming inspection criteria and supplier quality requirements.
  • Lead supplier audits, corrective action requests (SCARs), and supplier development activities.
  • Collaborate with procurement and engineering to qualify new suppliers and manage approved supplier lists.
  • Monitor supplier quality performance metrics and drive improvement where needed.


Customer Quality Interface
  • Serve as the primary quality contact for customer complaints, returns (RMA), and quality escalations.
  • Lead customer complaint investigations, ensure timely and thorough root cause analysis, and implement effective corrective actions.
  • Support customer audits and quality-related inquiries.
  • Participate in new product development and design reviews (APQP, PPAP concepts where applicable) to ensure quality is designed in from the start.


Qualifications:
  • Bachelor's degree in Quality Assurance, Engineering, Manufacturing, Business Administration, or related field.
  • Preferred certifications include:
    • Certified Quality Manager (CQM) - ASQ (highly preferred)
    • Certified Quality Engineer (CQE) - ASQ
    • Six Sigma certification (Green Belt required; Black Belt preferred)
    • ISO 9001 Lead Auditor certification or equivalent quality systems certification
    • Lean Manufacturing certification (preferred, especially in industrial environments)
  • 5-10+ years of progressive experience in quality assurance, quality control, or manufacturing environments.
  • 2-5+ years of leadership or supervisory experience managing QA teams.
  • Demonstrated experience implementing and maintaining Quality Management Systems (QMS).
  • Experience with regulatory compliance (e.g., ISO standards, FDA, OSHA, or industry-specific requirements.)
  • Proven track record of leading teams, process improvement initiatives, and driving continuous improvement.


The expected salary for this position is between $86,985.00 and $116,995.00 per year. This range represents a good faith estimate for the position and actual compensation will be based on numerous factors including knowledge, location, skills, training and experience.

IDEAL employees enjoy a wide range of valuable benefits including:
  • Medical, Dental & Vision Insurance
  • Education Reimbursement
  • Wellness Programs
  • 401k with Company Match
  • Cash Balance Pension Plan

IDEAL values rest, personal time and community involvement facilitating these through several paid time off programs including:
  • Vacation
  • Personal Days
  • Volunteer Time
  • Holidays
  • Parental Leave


IDEAL INDUSTRIES, INC. is proud to be one of Newsweek's Global Top 100 Most Loved Workplaces and an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, or protected veteran status. We know when you honor relationships, success for all will follow. To learn more about us, visit www.idealindustries.com

About Company

IDEAL. The way every job should be.

J. Walter Becker founded IDEAL in 1916 and made a promise that is still an important part of the way IDEAL operates today: ";An IDEAL product will provide a value greater than the price paid for it. Service is a part of the product."; Becker's foundational principle represents our everyday commitment to you. It's the driving force behind our partnerships with the world's leading distributors, a state of the art delivery system, outstanding customer and technical support and variety of operational benefits designed to save you time and money. It means we're proud of the way we do business.

IDEAL brings you products that make your job easier; products that you can rely on, with warranties you can trust; products that are available whenever and wherever you need them. Every IDEAL product comes with the promise made by our founder more than 90 years ago.

In addition to serving the needs of electrical and datacomm professionals, IDEAL INDUSTRIES, INC. also serves the high power interconnect market needs through Anderson Power Products, the environmental monitoring and measurement market through Casella Measurement, and the telecommunication industry through Trend Communications. Please visit their respective websites for more information.

Products

Over 6,000 items make up the IDEAL family of products including some whose names have become synonymous with their function. Wire-Nut® Wire Connectors, Yellow 77® Wire Pulling Lubricant and T®-Stripper Wire Strippers are products which have found their way into the tool bags of professionals and solidified the IDEAL reputation as an engineer of innovative and trustworthy products.

Markets

The wide variety of products offered by IDEAL reaches the professionals of many markets. From the electrical contractor and datacomm technician to the production engineer and plant manager, the job is easier when IDEAL lends a helping hand. Our divisions are dedicated to the professionals we serve: Electrical, DataComm, Wire Processing and OEM Engineered Solutions.

Electrical

Residential, commercial and industrial electricians have come to depend on IDEAL for quality electrical products. Our electrical line contains just about everything an electrician might need for an easier, more efficient job: industry standard wire connectors, fish tapes, benders, wire pulling lubricants, wire strippers, hand tools and wire management supplies...and a comprehensive family of rugged, versatile and easy-to-use test and measurement instruments.

DataComm

IDEAL DataComm is dedicated to helping telecomm/datacomm professionals keep networks up and running. The system of products we've thoughtfully crafted ensures the highest-quality terminations with the ease-of-use you'd expect from IDEAL. Our DataComm line includes tools and products for paired conductor, coax and fiber optic cabling.

Wire Processing

The goal of IDEAL Wire Processing is to design machines and tools that will help engineers and plant managers increase efficiency, save costs and reduce labor. A full line of bench-top and hand-held tools and products make commercial and aerospace wire processing accurate and affordable.

OEM Engineered Solutions

IDEAL has solutions that allow manufacturers to make their electrical connections quickly and reliably with a full line of high-quality connectors and application equipment. Designed with the requirements of the OEM, standards agencies, and the electrical code in mind, IDEAL products offer the innovation, quality, and reliability manufacturers require.

Facilities

Reaching our distributors and customers requires that we have facilities all over the world. IDEAL headquarters are located in Sycamore, Illinois with manufacturing plants in Sycamore and DeKalb, Illinois; Sterling, Massachusettes; Ajax, Ontario, Canada; Fermoy, Ireland and in England, Spain and China. International sales facilities are located in Canada, England, Germany, Australia, China, Brazil, Mexico and Puerto Rico. Five distribution centers across the U.S. provide quick and accurate deliveries of the IDEAL product line.

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