Quality Assurance Manager

About Leviton

At Leviton, we build what's next to light, power, and connect everyday spaces, from electrical to lighting, to data networks, and energy management. With over 115 years of history, Leviton develops thoughtful solutions that help make its customers' lives easier, safer, more efficient, and more productive. We recognize that our people are our greatest asset. We ASK questions, EMBRACE challenges, SEEK new perspectives, and ANTICIPATE what comes next. It's about each person bringing skills and passion to a challenging and constantly changing world.

About The Role

The Plant Quality Manager, reporting to the Senior Director of Quality, is responsible for implementing and continuously improving the activities of quality control, quality assurance, the plant quality management system (QMS), incoming inspection, customer outgoing quality, new product introduction and the metrology / test labs to ensure product meets the engineering, regulatory safety agencies and corporate requirements. This role is also responsible to institute and promote a plant quality culture where plant management and the plant staff own quality improvement reducing overall cost of poor quality. Additionally, the role is responsible for implementing a robust problem-solving process that effectively addresses internal and external non-conformities and constantly looking for new technology and solutions in the industry for quality improvement and associated fields.

Responsibilities

Quality Strategy and Leadership

• Develop, implement, and maintain the plant quality strategy aligned with the corporate quality and business objectives.
• Lead, coach, develop existing and hire best talent (engineers, technicians, inspectors, lab staff) to build a culture of prevention, problem solving, and continuous improvement.
• Act as the primary quality contact for plant leadership, customers, and regulatory agencies.

Customer Quality & New Product Introduction

• Improve external customer quality with end customers. Use problem solving methodologies such as 8D, DMAIC, PDCA to improve customer DPPM until we achieve zero defects with our customers.
• Monitor and improve warranty costs related to customer non-conformances.
• Supports New Product Introduction through training and implementation of the Product Approval Committee (PAC) / APQP process.

Quality Management System (QMS)

• Own, maintain and improve the plant QMS in accordance with ISO standard and safety regulatory requirements.
• Ensure IS09001 internal and external audits are adding value and are promoting process KPIs performance continuous improvement.
• Ensure procedures, work instructions, forms and records are controlled, current and effectively implemented across all departments.
• Monitor and report quality KPIs (DPPM, FPY, COPQ, audit results, customer complaints) and lead actions to achieve targets.

Quality Control

• Establish and maintain in-process and final inspection plans, sampling strategies, and control plans for finished goods products and components.
• Ensure proper use of SPC, control charts and visual/measurement standards on the shop floor.
• Implement processes to ensure proper line set-up per control plan and internal and corporate standards to produce good quality products.
• Lead containment, root cause analysis, and corrective actions for non-conforming product, process escapes and field issues.
• Collaborate with Production, Engineering and Maintenance to ensure process capability, equipment qualification, and robust change management processes.
• Implement, maintain and continuously improve the process of outgoing quality control (OQC) to ensure product compliance to Leviton Engineering Specifications.

Quality Assurance

• Approve and validate new products, processes and design changes, from a quality perspective (Endorsement, LIRs, QAVs, Validation testing and both temporary and permanent changes via ECRs/Deviations).
• Ensure compliance with regulatory agency requirements applicable to electrical products (UL, CSA, ETL, NOM etc.)
• Implement an effective risk management process using the FMEA tool, control plans and drive preventive quality improvements during the whole product life cycle.
• Implement an effective process with tools such as Layered Process Audits to promote a quality culture where operators, engineers and managers follow standards and non-compliant events are addressed effectively with proper corrective actions.

Incoming Inspection and Supplier Interface

• Oversee incoming inspection of raw materials, either outsourced or made by sister plants per engineering drawings, part specifications, and corporate standards.
• Define acceptance criteria, inspection levels and sampling plans for critical and high-risk items.
• Coordinate with corporate or plant supplier quality teams to manage supplier performance, non-conformances, and SCARs using 8D problem solving.
• Ensure timely disposition of incoming non-conforming material to prevent line disruptions.

Metrology and Test Laboratories

• Manage quality metrology and test labs, ensuring availability, capability and proper utilization of measurement and test equipment.
• Oversee calibration programs for gauges, fixtures, and measuring instruments; ensure traceability and compliance with standards.
• Ensure test methods, measurement systems, and lab procedures are validated, documented, and continuously improved (including MSA, GR&R where applicable).
• Plant and maintain lab capacity to support NPI, engineering changes, investigations, and routine product verification.
• Implement an engineering and regulatory agencies follow-up product testing program to ensure compliance with requirements.

Continuous Improvement and Quality Culture

• Lead and participate in continuous improvement projects (Lean, Six Sigma, Kaizen) to reduce defects, scrap, rework, and cost of poor quality.
• Promote data driven decision making through regular analysis of quality data and trends.
• Champion standardization and best-practice and lessons learned sharing across shifts, lines and sister plants as applicable.
• Monitor latest quality trends and new technology through involvement in professional societies/events such as the Corporate Quality Summit, conferences, and manufacturing shows to stay abreast of technical developments in quality assurance and associated fields.
• Foster and improve quality culture throughout the manufacturing plant through training programs, recognition initiatives, and cross-functional quality awareness campaigns to embed prevention mindset and accountability at all levels.
• Champion shop-floor problem solving, coaching production operators, line leaders, supervisors on quality tools and standards.

Others

• Manage annual financial and headcount budgets with the mindset of continuous improvement on overall cost of poor quality.
• Support and promote the Sustainability program CN 2030.

Education and Experience

• Bachelor's degree in engineering (Electrical, Industrial, Mechanical, or related).
• 7+ years' quality experience in manufacturing; 3+ years leading plant-floor quality teams and experience working for more than one company, preferably across multiple companies.
• Proven experience in ISO 9001:2015 QMS implementation, audit leadership.
• Strong knowledge of quality tools (8D, FMEA, Control Plans, SPC, MSA)
• Proven experience managing inspection, metrology, and/or test labs.
• Demonstrated success working cross-functionally with Operations, Engineering, Supply Chain, and Customers.
• 5+ years of experience in PCBA manufacturing companies.
• Bilingual – Spanish and English (for Plants outside the US) professional proficiency required.
• Strong leadership and people development skills to drive major improvement initiatives.
• Analytical, data-driven decision making and problem solving.
• Proficient in statistical techniques and tools.
• Excellent communication skills (written and verbal), including ability to lead resolution of complex problems with cross-functional teams and lead customer and audit discussions.
• High attention to detail, organization, and follow-through.
• Ability to balance engineering requirements, operational realities, and business priorities.
• Demonstrated experience changing cultural behaviors.

Travel

• Up to 10% including internationally.

The future looks brighter than ever. Join our team now