KEY RESPONSIBILITIES:
Strategic Quality Leadership:
- Develop and implement comprehensive quality systems (TQMS) that support long-term manufacturing goals and maximize customer satisfaction.
- Lead the cultural shift from "Inspect & Reject" to "Predict & Prevent", embedding quality thinking at every level of the organization.
- Drive strategic initiatives that align quality objectives with business growth, product innovation, and operational excellence.
- Foster a proactive, quality-first culture focused on continuous improvement and customer-centric thinking.
Systems & Process Optimization:
- Build and maintain scalable quality management systems using SPC methodologies to monitor, evaluate, and control product and process quality in real-time.
- Oversee systems addressing customer concerns, corrective actions (internal and supplier), nonconforming materials, and root cause analysis (8D process).
- Lead plant-wide audits to ensure compliance with Trex quality standards, and drive continuous improvements based on findings.
- Engage the organization in Layered Process Audits (LPA) and outgoing quality audits for immediate feedback and corrective actions.
- Harmonize claim language between the Consumer Call Center, QA, and Manufacturing teams to ensure consistency and clarity.
- Continuous Improvement & Problem Solving:
- Champion continuous improvement initiatives to reduce defects, enhance product consistency, and improve overall process efficiency.
- Identify key improvement areas, prioritize actions based on data, and lead cross-functional teams to implement sustainable solutions.
- Utilize Lean, Six Sigma, and other structured problem-solving tools to drive measurable improvements in product and process quality.
Data-Driven Decision Making:
- Establish and monitor Key Performance Indicators (KPIs) to evaluate quality system effectiveness and guide strategic decisions.
- Analyze complex data sets to identify trends, inform process improvements, and present actionable insights to plant leadership.
- Relate consumer-critical product attributes to manufacturable parameters to improve consistency and reduce variability.
- Calculate and report the true Cost of Poor Quality (COPQ) and maintain a quality KPI scorecard for the plant.
- Explore and implement new technologies like AR, VR, and AI to optimize quality systems and processes.
Collaboration & Influence:
- Partner with Engineering, R&D, Continuous Improvement, and Supply Chain to integrate quality into product development and manufacturing processes.
- Collaborate with Purchasing to improve supplier quality and strengthen the supply chain.
- Act as a quality subject matter expert, guiding and influencing cross-functional teams toward quality-driven decision-making.
- Engage directly with customers and field teams to stay attuned to the Voice of the Customer (VOC).
- Benchmark competitors to ensure Trex maintains a performance leadership position within the industry.
Documentation & Compliance:
- Maintain and audit quality documentation and procedures in accordance with Trex Quality Management System (TQMS) and relevant regulatory standards.
- Lead and support change management activities, ensuring smooth transitions with a focus on maintaining and improving quality outcomes.
REQUIRED QUALIFICATIONS:
- Bachelor's degree in Engineering or a related field.
- Minimum of 6 years of experience in quality roles, including at least 3 years in a management or leadership capacity within a manufacturing environment.
- Strong background in building and scaling complex quality systems.
- Six Sigma Green Belt or Black Belt certification preferred.
- Expertise in quality management tools (APQP, 8D, A3, FMEA, SPC, PPAP, etc.) and data-driven problem-solving.
- Proven ability to lead cross-functional teams, drive strategic initiatives, and influence at all organizational levels.