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Vehicle Quality Assurance Engineer — Key Responsibilities and Required Skills

💰 $ - $

EngineeringAutomotiveQuality Assurance

🎯 Role Definition

The Vehicle Quality Assurance Engineer is responsible for ensuring that vehicles and vehicle subsystems meet safety, reliability, performance and customer satisfaction targets throughout development, prototype validation, and production launch. This role combines hands-on test execution, data-driven defect analysis, supplier quality oversight, and the creation and maintenance of quality artifacts (DVP&R, control plans, PPAP packages). The ideal candidate applies automotive quality standards (IATF 16949, ISO 26262) and continuous improvement methodologies (Six Sigma, 8D, PDCA) to prevent defects, drive corrective actions, and optimize manufacturing processes.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Quality Engineer (Component or Supplier Quality)
  • Test or Validation Engineer (Vehicle systems such as powertrain, chassis, electrical)
  • Manufacturing or Process Engineer transitioning into QA

Advancement To:

  • Senior Vehicle Quality Assurance Engineer / Lead QA Engineer
  • Quality Manager / Program Quality Lead
  • Director of Quality or Head of Vehicle Validation

Lateral Moves:

  • Reliability Engineer / Durability Engineer
  • Manufacturing Process Engineer
  • Product Development Engineer (Systems or Integration)

Core Responsibilities

Primary Functions

  • Develop, own and execute vehicle-level and subsystem validation plans (DVP&R) that trace requirements to tests, acceptance criteria, test methods and test results to ensure vehicles meet safety, durability, performance and regulatory targets.
  • Lead cross-functional root cause analysis (8D, Ishikawa, Pareto) for field and development defects, define containment actions, verify corrective actions, and maintain issue tracking until closure with evidence-based validation.
  • Create and maintain process and product quality artifacts including APQP deliverables, PFMEA/DFMEA, control plans, process flows, production part approval (PPAP) packages, and design verification matrices, ensuring traceability and compliance with customer and regulatory requirements.
  • Plan, coordinate and execute component and full-vehicle testing (durability, vibration, NVH, thermal, climatic, EMC, electrical, battery/EV systems, ADAS functional) in lab and on-road environments; document test setups, calibrations, and results for engineering review.
  • Define and manage quality gates throughout vehicle program lifecycle including prototype validation, pilot production, and full-scale production launches; ensure timely closure of open actions to meet program milestones.
  • Perform statistical data analysis (SPC, MSA) on manufacturing and test data to detect trends, process shifts, and nonconformances; recommend process adjustments and controls to improve yield and reduce escapes.
  • Drive supplier quality engineering activities: conduct supplier audits, assess supplier control plans, review PPAP submissions, and collaborate with suppliers to reduce defects and improve material/process quality.
  • Work closely with design engineering to perform DFMEA reviews, provide feedback on manufacturability and testability, and ensure design changes are validated and released with revised quality documentation.
  • Lead investigations for warranty returns and field incidents, coordinate multi-disciplinary corrective action teams, quantify customer impact, and develop preventive measures to reduce future warranty costs.
  • Define validation test procedures, acceptance criteria and instrumentation requirements; oversee data acquisition setups and ensure test integrity and repeatability.
  • Validate and verify safety-critical systems against ISO 26262 functional safety requirements; participate in safety analyses, verification plans, and safety-related test execution.
  • Manage and support production launch quality activities on-site at OEM or supplier plants: run production line audits, perform first article inspections, support containment, and ensure launch metrics (PPM, scrap, rework) are met.
  • Create and present concise, data-driven quality reports and dashboards for program leadership, emphasizing risk, corrective actions, and progress toward quality targets.
  • Implement continuous improvement projects (Six Sigma, Kaizen) to reduce variation, improve process capability and lower cost from quality escapes; lead or support DMAIC projects as project champion or team member.
  • Collaborate with calibration and controls teams to validate ECU and software updates, verify release behavior on vehicle, and coordinate software regression testing related to quality defects.
  • Oversee non-conformance management: define defect classification, disposition processes, and rework instructions; ensure accurate documentation in quality management systems (QMS).
  • Support design reviews and prototype build reviews with quality input on testability, reliability margins, and manufacturing constraints to prevent late-stage changes and rework.
  • Coordinate cross-functional problem-solving during vehicle integration and system-level testing to ensure timely identification and mitigation of issues that impact safety or customer experience.
  • Develop and deliver quality trainings for manufacturing operators, assembly technicians and supplier personnel on critical quality topics, inspection criteria and containment procedures.
  • Lead measurement system analysis (MSA) and coordinate lab calibrations to ensure test equipment and measurement devices are accurate, repeatable, and traceable.
  • Support change control processes to evaluate engineering change requests (ECRs) and engineering change orders (ECOs) for quality impact, required revalidation and supplier notification.
  • Maintain compliance with regulatory, customer, and internal quality standards including IATF 16949, ISO 9001, regional vehicle safety regulations, and OEM-specific requirements.
  • Support cross-functional risk assessments and develop mitigation plans for high-risk integration areas (e.g., battery pack integrity, steering/ADAS interactions, braking systems).
  • Lead or participate in multi-site quality alignment activities for global programs to ensure consistent quality processes and harmonized metrics across plants and suppliers.

Secondary Functions

  • Support ad-hoc field data requests, warranty trend analysis, and exploratory data analysis to identify emerging quality risks.
  • Contribute to the organization's quality strategy and roadmap by providing insights from validation and production learnings.
  • Collaborate with business units (engineering, manufacturing, purchasing, service) to translate quality needs into technical requirements and supplier expectations.
  • Participate in program management cadence and agile ceremonies to align quality deliverables with program timelines and sprint goals.
  • Assist procurement and supplier development in qualifying new suppliers and materials, including technical assessment and on-site capability audits.
  • Support continuous improvement workshops and mentor junior engineers on root cause analysis techniques, measurement systems, and quality tools.

Required Skills & Competencies

Hard Skills (Technical)

  • Vehicle-level validation and test planning (DVP&R) with traceability from requirements to test cases and results.
  • Strong experience with APQP, PPAP, PFMEA/DFMEA, control plans, and production launch quality processes.
  • Proficient in root cause analysis methodologies (8D, 5-Why, Ishikawa) and corrective/preventive action implementation.
  • Statistical process control (SPC), measurement system analysis (MSA), capability studies and use of statistical tools (Minitab, JMP, Python/R for analysis).
  • Hands-on test execution experience: NVH, durability, thermal, EMC, electrical/EV systems, ADAS validation and vehicle dynamics testing.
  • Experience with ISO 9001, IATF 16949, and knowledge of ISO 26262 functional safety processes and evidence requirements.
  • Familiarity with vehicle electrical/electronic systems, ECU calibration basics, CAN/FlexRay diagnostics and log data interpretation.
  • Experience managing supplier quality: supplier audits, PPAP reviews, containment plans, and supplier corrective action (SCAR) processes.
  • Proficiency with quality management systems (QMS), PLM/PDM systems, test data acquisition, and defect tracking tools (JIRA, SAP QM, Teamcenter).
  • Six Sigma training (Green Belt or Black Belt preferred) and continuous improvement methodologies (DMAIC, Kaizen).
  • Ability to write and review technical reports, control plans, test procedures, and regulatory submissions.
  • Knowledge of manufacturing processes and tooling issues that affect assembly quality, fit-and-finish, and dimensional tolerance control.

Soft Skills

  • Strong analytical and systems-thinking skills with the ability to translate complex data into clear, actionable insights.
  • Excellent verbal and written communication skills for cross-functional collaboration and customer-facing interactions.
  • Proven leadership and facilitation ability to drive multi-disciplinary corrective action teams to closure.
  • High attention to detail and focus on delivering high-quality documentation and evidence for audits and regulatory needs.
  • Adaptability under changing program priorities and ability to multitask across concurrent vehicle programs.
  • Customer-focused mindset with the ability to prioritize issues based on customer impact and business risk.
  • Coaching and mentoring skills to develop junior engineers and technicians in quality processes and tools.
  • Conflict resolution and negotiation skills when working with suppliers and internal stakeholders to reach practical solutions.
  • Project management fundamentals and ability to manage deliverables, schedules and milestone commitments.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor's degree in Mechanical Engineering, Automotive Engineering, Electrical/Electronics Engineering, Mechatronics, Materials Science or related engineering discipline.

Preferred Education:

  • Master's degree in Automotive Engineering, Systems Engineering, Reliability Engineering, or MBA with technical background.
  • Professional certifications such as Certified Quality Engineer (CQE), Six Sigma Green/Black Belt, or IATF 16949 Auditor.

Relevant Fields of Study:

  • Mechanical Engineering
  • Automotive Engineering
  • Electrical / Electronics Engineering
  • Mechatronics / Systems Engineering
  • Materials Science / Manufacturing Engineering

Experience Requirements

Typical Experience Range: 3–10 years of progressive experience in automotive quality engineering, vehicle validation, or supplier quality.

Preferred:

  • 5+ years of direct vehicle-level validation, production launch, or supplier quality experience in the automotive industry.
  • Demonstrated history of leading root cause analyses, running lab and road tests, and achieving measurable quality improvements during vehicle programs.
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