PCI Engineer

Job description

Role Purpose

The PCI (Process Control Inspection) Engineer is responsible for ensuring Full Sheet (FS) product quality through sampling inspection, statistical analysis, and process data mining. This role drives continuous quality improvement by establishing robust quality control systems, leading cross-functional problem solving, and collaborating with Production, Engineering, and Project teams using PDCA / DMAIC (Define, Measure, Analyze, Improve, Control) methodologies.

Key Responsibilities

• Product Quality Monitoring & Risk Management
• Monitor FS production process KPIOVs (Key Process Input Output Variables) and daily product quality performance.
• Conduct quality risk assessments for internal quality issues.
• Manage quality-risk lots, including containment, disposition, and follow-up actions.
• Track and analyze internal and external quality trends using statistical methods, including SPC (Statistical Process Control) and QC tools.
• Quality Issue Investigation & Corrective Action
• Lead and conduct 8D analysis for internal and customer quality issues.
• Coordinate plant cross-functional teams (Melting, Engineering, Production, QA) to identify root causes and implement corrective and preventive actions.
• Respond to customer complaints and provide complete 8D reports.
• Act as AQA (Advanced Quality Assurance) interface to support offload FS receiving plants for quality issue investigation and resolution.
• Process Control & Quality System Architecture
• Initiate data analysis to identify correlations between quality outputs and process inputs.
• Propose and maintain quality architecture, control plans, and sampling plans to meet customer requirements.
• Architect and enhance FS quality management systems using digital transformation (Dᵗ) tools to improve efficiency and data visibility.
• Build and continuously optimize Quality Control Plans and sampling strategy strategies.
• Continuous Improvement & Project Leadership
• Lead and participate in quality improvement projects using a-DMAC / DMAIC methodology (Define, Measure, Analyze, Improve, Control).
• Support EEPs (Engineering Experience Plan) and engineering experiments with data analysis and quality validation.
• Collaborate with plant-side, regional, and worldwide teams on continuous improvement and new product development quality architecture.
• Drive cross-regional FS offload quality improvement with Division QA.
• Audit, Qualification & Compliance
• Conduct routine shop floor audits to ensure process quality assurance.
• Support and participate in internal and external ISO audits.
• Lead tank start-up quality support, validation, and tank qualification activities.
• Support customer qualification activities together with account QA. Experiences/Education

Required Education & Experience

• Bachelor's degree or above in Engineering or related field
• Minimum 3 years of experience in quality management and quality issue handling Required Skills:

Digital Transformation (Dᵗ) skills

• Python, Power BI, Power Automate, etc.
• Strong logical thinking and a data-oriented mindset, with familiarity in methodologies such as DMAIC and MEE (Manufacturing Engineering Excellent)
• Proven problem-solving and decision-making skills (e.g., Kepner-Tregoe)
• Strong statistical and quality tool capability (SPC, 8D, QC 7 tools, Six Sigma)
• Strong coordination and facilitation skills
• Fluent English in speaking, reading, and writing
• High ownership, willing to take challenges and set high standards Soft Skills:
• Strong communication and cross-functional collaboration skills
• Influencing without authority
• Structured thinking and execution discipline Experiences/Education
• Desired
• Solid knowledge of melting processes
• Certified Quality Engineer (CQE) or Certified Quality Technician (CQT)