Sr. FMEA Moderator

As Sr. FMEA Moderator you lead Design and Process FMEAs from product development to series production. You guide cross-functional teams through the AIAG-VDA method, make sure every risk is understood, prioritized and controlled - in the design, on the shop floor and in the Control Plan - and coach other engineers to become moderators. Ideal for Quality, Advanced Quality (APQP) or Process Engineers who already facilitate DFMEA/PFMEA (AMEF) workshops. The role reports to the Team Leader Quality, supports projects and plants in several regions (remote and on site), and the work model is hybrid (3 days in office, 2 remote). Main Responsibilities • Plan, moderate and document DFMEA (system, software, hardware, mechanics) and PFMEA (manufacturing and logistics) according to the AIAG-VDA FMEA Handbook, using APIS IQ-RM PRO. • Guide teams step by step through the 7 AIAG-VDA steps: block/boundary and P-diagrams, structure trees, function and failure nets, risk analysis with Action Priority (AP) and optimization. • Ensure the cascade from requirements to DFMEA, process flow, PFMEA, Control Plan and work instructions, including the special characteristics list. • Support PFMEA in production: line walks, process flow analysis, linking prevention and detection controls with the Control Plan, and managing quality concerns (QC) through the FMEA. • Drive launch readiness of new lines and changes: PFMEA risk analysis before dry runs and Run@Rate, and verification of error-proofing (poka-yoke) devices with red rabbits. • Feed 8D results, lessons learned and Yokoten back into DFMEA/PFMEA; plan and lead Reverse PFMEA and periodic reviews of generic FMEAs. • Confirm the methodical and formal correctness before release; lead FMEA reviews and line walks, the approval workflow and the documentation in the FMEA document management system. • Track actions to closure, verify their effectiveness and escalate delays; report FMEA status, KPIs and maturity to project and plant management. • Lead management and customer FMEA reviews and support audits, ensuring compliance with customer-specific requirements (CSR). • Coach engineers and moderator candidates (tandem moderation, feedback) and deliver FMEA workshops and awareness trainings for project and production teams. • Improve FMEA templates, generic FMEAs and digital/AI-assisted FMEA checks. Language Required: Advanced English (C1) Availability to travel: Yes Professional Experience (years): 8+ years Mandatory • Bachelor's degree in Mechanical, Electrical/Electronic, Mechatronics or Industrial Engineering, or a related field. • 8+ years of experience in automotive (or a similarly regulated industry) product development, process engineering or quality, including 3+ years leading DFMEA and/or PFMEA sessions as moderator or facilitator. • Proficient in the AIAG-VDA FMEA Handbook (7-step approach, Action Priority, FMEA-MSR) and able to teach each step to engineering and plant teams. • Hands-on use of FMEA software within the last two years - APIS IQ-RM PRO preferred. • Solid knowledge of APQP/PPAP and the core tools: Process Flow, Control Plan, special characteristics, MSA and SPC. • Experience with problem solving (8D, 5 Why, Ishikawa) and with lessons learned / Yokoten. • Working knowledge of IATF 16949, ISO 9001 and VDA standards. Desirable • Shop-floor launch experience: dry runs, Run@Rate/PPAP, error-proofing verification with red rabbits, line walks. • System, software or hardware FMEA and its link to Functional Safety (ISO 26262, FMEDA) or Automotive SPICE. • FMEA moderator qualification (e.g., AIAG & VDA FMEA or Bosch FMEA Moderator) or experience as FMEA trainer. • DRBFM, Quality Gates, Lean Six Sigma Green Belt, VDA 6.3 process auditor or IATF 16949 internal auditor. • Data an