Roadmap of Quality Engineer – Step by Step Guide

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Roadmap

Hello, want to start a career as a quality Engineer? Want to know the exact roadmap for quality engineer?

After all you are here for to know about everything Quality Engineer should know?. Many of you already start working in Quality Field. And you are eager to know in deeper concepts and meaning of true Quality Engineer.

We are experience professional going through the same phase. And now successfully completed our milestone to position with all learnings and be the person as successful Quality Engineer.

Know the skills and knowledge Quality Engineer should have.

Here we are going to learn the importance of Quality Engineer in organization. And also know

What Quality Engineer is and why are they important?

The quality engineer is the professional who understand the product, process and service quality. He can develop the operation of quality system.

Quality Engineer is very important in organization because he knows the concept related to data analysis, techniques, methodology to apply on problem solving and improving the product, process and management system.

In this guide, you will find the roadmap, tolls, skills, concept and will be able to start a progress in your career by following the steps.

So, without further delay, here are the steps:

Types of industries

Step 1: Know Industry Type

Product and Processes

Step 3: Product and Processes

knowledge

Step 2: Organization knowledge

skills and tools

Step 4: Quality Engineer Skills and Competences

Step 1: Know Industry type you are in

The manufacturing industries plays vital role in the progress of country. Lot of businesses is fall in the segment of manufacturing. As per labor statistics classifies into hundreds of subsections.

Here are the five types of manufacturing industries that are predominant the market.

  • Metal Manufacturing
  • Apparel and textile
  • Gadgets, computers and Electronics
  • Oil, chemical & Plastics
  • Food Production

Step 2: Organizational Knowledge

Yes, this is the step where you must have the organizational knowledge such as the organizational structure. What are the departments in your company and who is leading those department. The function of those with each structure elements.

Also importantly what is exactly organizational knowledge and its type, let’s see below.

What is organizational knowledge?

It is the particular knowledge of an organization you get from collective experience or from the individual experience of person. This knowledge can be use to attain the organizational objective.

The organization knowledge includes the employee handbooks, company standards, product knowledge, manuals, intellectual property, customer communications, and lessons learnt of success and failure.

organization knowlege

“Determine the knowledge necessary for the operation of its processes and to achieve conformity of products and services. This knowledge shall be maintained and made available to the extent necessary. When addressing changing needs and trends, the organization shall consider its current knowledge and determine how to acquire or access any necessary additional knowledge and required updates.

NOTE 1: Organizational knowledge is knowledge specific to the organization; it is generally gained by experience. It is information that is used and shared to achieve the organization’s objectives.

NOTE 2: Organizational knowledge can be based on: a) Internal Sources (e.g., intellectual property, knowledge gained from experience, lessons learned from failures and successful projects, capturing and sharing undocumented knowledge and experience; the results of improvements in processes, products and services); b) External Sources (e.g., standards, academia, conferences, gathering knowledge from customers or external providers).”

Clause 7.1.6. Knowledge, ISO 9001:2015 Quality Management Systems — Requirements

Organization knowledge is very important because, it will help you in decision making, innovation, learning and problem solving

So basically every quality engineer has below types of organizational knowledge.

Types of organizational knowledge

1. Tacit knowledge

It is difficult to get. such as implicit knowledge or wisdom. This is found such as in human mind and purely base on experience. It is hard to get because if we consider the salesperson. It has a good skills and it is hard to get transfer to other. And it is not easy for competitors to duplicate. Therefore the organization have the competitive advantage.

2. Explicit knowledge

It is the knowledge in the form of documents and other written medias. Good examples of these knowledge is Manuals, Documented procedures, Quality standards etc.

3. Individual knowledge

Individual knowledge is the best beginning of learnings in any organization. The good organization is the one where how knowledge is share and transfer to others by individuals. It includes the personal abilities, skills, learnings, approach to problem solving and communications. It will help in how every person is prioritize in organization and how he will perform the tasks.

Individual knowledge includes the skills, learning, personal abilities, and communication preferences that influence how a person prioritizes, seeks information, and otherwise performs work tasks.

4. Collective knowledge

It is generally rules, processes and procedures on how everyone is interact and share the knowledge in problem solving. It will guide peoples on how to communicate and solve problems.

Step 3: Product and Processes

If you want success as a competent quality engineer, then you must have a good knowledge about the product and process in your organization.

Basically when you start your career in Quality field, you start with the product knowledge.

1. Product

Product is nothing but the final output in the industry. It can be anything Physical or virtual. In Manufacturing the final outcome such as car, axel, door, clutch, gear, Rod etc. In Software industry it may be software.

A product is any item or service you sell to serve a customer’s need or want.

Now the best part is how you will get the product information.

You should understand the product by knowing the requirement of customer. What are the characteristics we are achieving on the product so that this product is meet our customer fitment.

Product knowledge is very crucial before going into process depth.

2. Process

Every quality engineer should know about the processes in the industry where he is working with.

What is Process?

Lets see from the definition perspective. Process is the set of activity where inputs convert to output.

Process

So to get expertise in process, You need to go through the on job training process. Please learn how the raw materials, or incomming parts pass through our manufacturing processes and how the outcome is produce. This is nothing but the product from the particular process.

Work as an entry level unskilled Graduate Engineer Trainee (GET). Learn different types of equipment and will get to see what kind of product is being made and how.

Spend your break time just by walking around the assembly line or process line. Talking to people who are in charge of other operations. And to find out what is being done in each process step.

To learn the more, do job in the biggest factory / industry that is making the very complicated products from the many materials.

for example; Automotive plants, use almost every manufacturing process at some point.

Here is what you need to learn from process point

  1. Process flow: How processes are linked
  2. What are the steps in processes
  3. Process characteristics: These are responsible to get our product as per requirement
  4. Operating procedures (SOP’s)
  5. Inspection methods: Different types of equipment and instruments
  6. Documentation on process line and what is purpose of them
  7. Process standards and process yields and outputs.

Step 4: Quality Engineer Skills and Competences :
Roadmap of Quality Engineer

This is the most important step as you need to learn as a quality engineer. Here in this step you see all skills and competencies that you should learn in details.

Basically some of the topics are we already covered in above steps but still to link with full roadmap you will see them below.

As per the ASQ (American Society for Quality) you must know the content as a as Certified Quality Engineer. We will list down all topics which is mention in ASQ body of knowledge.

You must know these skills and tool to stand out as Quality Engineer in Organization. Don’t wasting your time, Lets jump to the topics.

The content in divided in 7 categories

Body of knowledge
  1. Management and Leadership
  2. The Quality System
  3. Product Process & Service design
  4. Continuous Improvement
  5. Product and Process Control
  6. Quantitative Methods and Tools
  7. Risk Management

1. Management and Leadership

  1. Quality Philosophies and Foundations
    1. Continuous improvement tools,
    2. lean, Six Sigma, theory of constraints
    3. statistical process control (SPC)
    4. Total Quality management
    5. leadership principles (including Deming’s 14 points)
  2. The Quality Management System (QMS)
    1. Strategic planning
    2. Deployment techniques
      1. Benchmarking
      2. Stakeholder
      3. Performance
      4. Project management
    3. Quality information system (QIS)
  3. ASQ Code of Ethics for Professional Conduct
  4. Leadership Principles and Techniques
  5. Facilitation Principles and Techniques
    1. Roles and responsibilities
    2. Facilitation tools
  6. Communication Skills
  7. Customer Relations
  8. Supplier Management
    1. Techniques
    2. Improvement
    3. Risk
  9. Barriers to Quality Improvement

2. The Quality System

  1. Elements of the Quality System
    1. Basic elements
    2. Design
  2. Documentation of the Quality System
    1. Document components
    2. Document control
  3. Quality Standards and Other Guidelines
  4. Quality Audits
    1. Types of audits
    2. Roles and responsibilities in audits
    3. Audit planning and implementation
    4. Audit reporting and follow-up
  5. Cost of Quality (COQ)
  6. Quality Training

3. Product, Process, and Service Design

  1. Classification of Quality Characteristics
  2. Design Inputs and Review
    1. Inputs
    2. Review
  3. Technical Drawings and Specifications
  4. Verification and Validation
  5. Reliability and Maintainability
    1. Predictive and preventive maintenance tools
    2. Reliability and maintainability indices
    3. Reliability models
    4. Reliability/Safety/Hazard Assessment Tools

4. Product and Process Control

  1. Methods
  2. Material Control
    1. Material identification, status, and traceability
    2. Segregation of Material
    3. Material classification
    4. Material review board
  3. Acceptance Sampling
    1. Sampling concepts
    2. Sampling standards and plans
    3. Sample integrity
  4. Measurement and Test
    1. Measurement tools
    2. Destructive and nondestructive tests
  5. Metrology
  6. Measurement System Analysis (MSA)

5. Continuous Improvement

continuous improvement
  1. Quality Control Tools
    1. Flowcharts
    2. Pareto charts
    3. Cause and effect diagrams
    4. Control charts
    5. Check sheets
    6. Scatter diagrams
    7. Histograms (Analyze)
  2. Quality Management and Planning Tools
    1. Affinity diagrams and force field analysis
    2. Tree diagrams
    3. Process decision program charts (PDPC)
    4. Matrix diagrams
    5. Interrelationship digraphs
    6. Prioritization matrices
    7. Activity network diagrams (Analyze)
  3. Continuous Improvement Methodologies
    1. Total Quality management (TQM)
    2. Kaizen
    3. Plan-do-check-act (PDCA)
    4. Six Sigma
    5. Theory of constraints (ToC) (Evaluate)
  4. Lean tools
    1. 5S
    2. Value stream mapping
    3. Kanban
    4. Visual control
    5. Waste (Muda)
    6. Standardized work
    7. Takt time
    8. Single minute exchange of die (SMED) (Evaluate)
  5. Corrective Action
  6. Preventive Action

6. Quantitative Methods and Tools

quantitative methods
  1. Collecting and Summarizing Data
    1. Types of data
    2. Measurement scales
    3. Data collection methods
    4. Data accuracy and integrity
    5. Descriptive statistics
    6. Graphical methods for depicting relationships
    7. Graphical methods for depicting distributions
  2. Quantitative Concepts
    1. Terminology
    2. Drawing statistical conclusions
    3. Probability terms and concepts
  3. Probability Distributions
    1. Continuous distributions
    2. Discrete distributions
  4. Statistical Decision Making
    1. Point estimates and confidence intervals
    2. Hypothesis testing
    3. Paired-comparison tests
    4. Goodness-of-fit tests
    5. Analysis of variance (ANOVA)
    6. Contingency tables
  5. Relationships Between Variables
    1. Linear regression
    2. Simple linear correlation
    3. Time-series analysis
  6. Statistical Process Control (SPC)
    1. Objectives and benefits
    2. Common and special causes
    3. Selection of variable
    4. Rational subgrouping
    5. Control charts
    6. Control chart analysis
    7. Pre-control charts
    8. Short-run SPC
  7. Process and Performance Capability
    1. Process capability studies
    2. The Process performance vs. specifications
    3. Process capability indices
    4. Process performance indices
  8. Design and Analysis of Experiments
    1. Terminology
    2. Planning and organizing experiments
    3. Design principles
    4. One-factor experiments
    5. Full-factorial experiments
    6. Two-level fractional factorial experiments

7. Risk Management

risk management
  1. Risk Oversight
    1. Planning and oversight
    2. Metrics
    3. Mitigation planning
  2. Risk Assessment
  3. Risk Control
    1. Identification and documentation
    2. Auditing and testing
  4. Failure and Mode Effect Analysis (FMEA)

Hope all the details are covered in this article. In future articles you will learn the detail concept for each tool and topics. If you want to get update of latest content please subscribe our newsletter, It is free.

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