Quality Engineer - Product

FuelCell Energy is seeking a Quality Engineer focused on product quality for power plant systems and quality during site construction and installation. The role proactively manages supplier quality, process qualification, inspections and audits, nonconformances and corrective actions, and continuous improvement aligned to the Quality Management System (QMS) and ISO-9001.

Role Overview

Own supplier quality and internal and external process qualification activities, including inspection and audit execution. Ensure balance of plant quality for FuelCell Energy Block Systems and verify that incoming materials and services meet established quality levels to support fuel cell project delivery.

Key Responsibilities

• Proactively ensure quality across balance of plant aspects for FuelCell Energy Block Systems and maintain incoming quality for purchased materials and services supporting fuel cell projects.
• Serve as the Quality interface and provide expertise within the Danbury Headquarters and with engineering groups to ensure product requirements are developed, understood, and met.
• Define Supplier Qualification processes, required process capability levels, and process controls to achieve Cost of Quality goals.
• Collaborate with suppliers to develop and approve Inspection and Test Plans (ITPs) for equipment, components, engineered systems, and contract manufactured skid systems.
• Verify supplier data, inspection and NDE reports, FAT reports, and completion of Mechanical and Electrical system inspections, checkouts, and tests. Conduct walk downs to confirm quality requirements from ITPs are satisfied.
• Perform inspections for installation and electrical execution, including wiring, termination, insulation testing, high potential cable testing, cold loop checking, earth continuity resistance testing, low ohm testing for bus bars, leak testing, and pre-commissioning activities.
• Drive Supplier Quality through supplier surveys, on-site audits, and follow-up audits to assess quality and manufacturing capabilities. Support supplier qualification, surveillance, and supplier development programs.
• Support site construction and product installation quality by conducting proactive QA/QC inspections that align with project procedures, standards, specifications, and approvals.
• Participate in the Design and Product Development Process by connecting product Critical to Quality (CTQ) requirements to process requirements and ensuring execution of related Verification and Validation plans.
• Qualify, control, monitor, and continuously improve internal and supplier processes using Lean Six Sigma tools.
• Execute Nonconformance Report activities and assist with Corrective Action entries in the ERP system to address supplier-related issues.
• Lead and participate in investigations, root cause analyses, and corrective and preventive action solutions using Lean Six Sigma tools within an 8D framework.
• Support continuous improvement of FCE QMS processes and related documentation.
• Develop, execute, and analyze quality-reporting measures. Periodically report to management on quality issues, supplier performance, non-conformances, corrective actions, trends, and losses, including plans for resolution and improvement.
• Perform Internal Audits in accordance with ISO-9001 and internal requirements.

Required Qualifications

• B.S. degree in Mechanical, Electrical, Chemical, or another related engineering degree.
• 5+ years of relevant experience in Quality Engineering.
• Six Sigma Green Belt or higher, or demonstrated application of statistical concepts (including Lean Six Sigma tool application and Reliability Engineering).
• Demonstrated use of Lean Six Sigma tools for manufacturing and supplier process qualification, control, root cause analysis, corrective action, and continuous improvement (e.g., MSA, DoE, SPC, FMEA, 5 Whys).
• Detail-oriented and methodical approach.
• Knowledge of inspection methods and techniques.
• Experience using standard mechanical, chemical, and electrical measurement instruments and functional gauges.
• Ability to read and interpret technical drawings and product requirements.
• Strong technical writing and communication skills.
• Ability to work effectively as a team member and independently, with cross-functional leadership skills.
• Excellent computer skills, specifically Microsoft Office Suite.
• Knowledge of ISO9001 standard, quality systems, policies, and procedures preferred.
• Experience with ERP and database system use preferred; experience with Microsoft Dynamics 365/ERP Solutions Quality software is a plus.
• Hands-on experience operating multimeters and process meters to complete I/O loop checks and troubleshooting is a plus.

Experience Areas

• Engineered equipment and skid assembly, ASME B31.3 welding, ASME pressure vessel fabrication, heat exchangers, gas compressors.
• Battery and UPS systems, VFDs, power distribution systems, low, medium, and high voltage switchgear and MCCs, motors and motor controls, transformers.
• PLC control systems, instrument and controls, electrical wiring checkout.
• Structural steel and sheet metal fabrication, welded fabrications, skid manufacturing.

Technologies

• Lean Six Sigma and Lean Six Sigma tools: MSA, DoE, SPC, FMEA, 5 Whys
• 8D framework
• ISO-9001 (ISO9001)
• ERP system, ERP and database system use
• Microsoft Office Suite
• Microsoft Dynamics 365; ERP Solutions Quality software
• Multimeters and process meters

Compensation

USD 105,500 - 116,750 per year

Location and Work Arrangement

Hybrid remote in Danbury, CT 06810

Travel and Physical Requirements

• Domestic and international travel required up to 70%.
• Ability to travel between CT locations regularly.
• Ability to obtain and maintain a valid passport and travel internationally without restriction is required.
• Ability to work physically in manufacturing plants or construction sites while wearing required PPE (e.g., safety gloves, hard hats, safety shoes).
• Lifting up to 25 pounds; standing and walking on concrete flooring or uneven installation/construction site surfaces for extended periods.
• Periodic bending and reaching; climbing ladders to inspect incoming, installed, or manufactured parts.
• Ability to hear or be aware of audible danger alerts.
• Ability to remain on feet and move between areas within a supplier shop or construction site.
• Computer work for extended periods required; ability to distinguish color.

Benefits

• 401(k)
• 401(k) matching
• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Vision insurance