Quality Engineer

ZipRecruiter; York; On-site; GBP 80,000 - 100,000; Full time

Job summary

An established industry player is seeking a Quality Manager to lead quality assurance initiatives at the plant level. This role involves overseeing the implementation and maintenance of the Quality System, ensuring adherence to ISO standards, and driving a culture of data-driven problem solving. The ideal candidate will have extensive experience in quality management, particularly within an iron foundry, and will be responsible for minimizing costs associated with poor quality. This is a fantastic opportunity to make a significant impact on quality improvement and customer satisfaction in a dynamic manufacturing environment.

Qualifications

• Mindestens fünf Jahre Erfahrung im Qualitätsmanagement in einer Gießerei.
• Starke Kenntnisse in fortgeschrittenen Qualitätsmanagementtechniken.

Responsibilities

• Leitung der Qualitätsmanagementsysteme und -prozesse im Werk.
• Durchführung von Ursachenanalysen und Implementierung von Korrekturmaßnahmen.

Skills

Qualitätsmanagement

Problemlösungsfähigkeiten

Kommunikationsfähigkeiten

Teamarbeit

Detailorientierung

Education

Bachelor in Qualitätsmanagement

Bachelor in Fertigungs-/Industrietechnik

Bachelor in Metallurgie

Tools

APQP

TQM

SPC

Job description

The Quality Manager provides leadership for quality assurance at the plant level, overseeing the implementation, maintenance, and development of the company's Quality System at each respective plant. In doing so, the Quality Manager will oversee adherence to the ISO quality system to support ISO certification. The Quality Manager will also take responsibility for minimizing the costs associated with poor quality (COPQ), including the reduction of scrap, customer rejections, and rework labor costs. In support of these goals, the Quality Manager is expected to lead by example through addressing internal quality concerns promptly and by working directly with customers to address and correct quality concerns with integrity and in a way that promotes customer satisfaction. The Quality Manager is also expected to promote a culture of data-driven problem solving and the implementation of process control techniques throughout the plant operation.

SUPERVISORY RESPONSIBILITIES:
Program Manager, Laboratory Manager, and Quality Technicians are direct reports.

ESSENTIAL FUNCTIONS OF THE JOB:

1. Work with the Plant Manager, Department Managers, and Group Leaders across all shifts to ensure that procedures and work instructions are implemented as required by the Company's Quality System.
2. Oversee scrap review procedures, chair regular scrap review meetings, manage a scrap reduction plan for systematically reducing scrap on high impact jobs. Nominate problematic jobs to the Plant Manager for engineering review or compatibility analysis.
3. Lead defect analysis and correction activities through formal root cause studies and other forms of structured problem solving (8D, 5 Why, Fishbone, etc.)
4. Work to develop and maintain an effective, integrated corrective action system and manage that system at the plant level. Ensure a disciplined and thorough problem identification and root cause analysis underpins process improvement decisions and that all aspects of the process are properly documented.
5. Work independently, with plant management, and with customers as needed to identify, act upon, and document necessary process improvements and corrective actions.
6. Oversee implementation of agreed upon corrective actions and ensure new processes are properly documented. Ensure supervisors and workers are properly trained and able to execute the new processes consistently. Provide formal feedback to company's staff and customers about the status of corrective actions and their results.
7. Manage the Non-Conformance System to ensure non-conforming material is effectively quarantined and dispositioned in a timely and documented manner.
8. Support the Program Manager in sample production. Collect data in the sampling process and provide results to the Program Manager so that data-driven decision making may be made during the job launch process. Collaborate with both the Program Manager and the Plant Manager to drive process compatibility and standardization with new job launches.
9. Evaluate the various plant manufacturing processes through observation, collection, and publication of process data to determine capabilities, variations, root causes, and improvement actions. Work with department staff and plant management to improve process control.
10. Support and implement statistical process control in critical areas in the plant.
11. Use quality improvement charts, dashboards, and technology to increase data visibility and empower every employee to understand the causes for scrap and drive change.
12. Work with engineering to develop predictive algorithms to reduce process variability, prevent scrap, and enhance process visibility.
13. Drive quality improvement through the use of contemporary quality management tools and techniques.
14. Implement and maintain a documented audit system to ensure that all quality and manufacturing processes are being performed to the prescribed standards.
15. Ensure the Quality System, including the Quality Manual, process procedures, work instructions, and other forms and documents, is properly maintained and effectively utilized. Ensure Donsco retains its ISO quality certification.
16. Oversee and maintain systems and procedures to inspect, test, audit, or otherwise ensure the quality of incoming material and supplies.
17. Lead in promoting a plant-wide quality culture; providing quality training and empowerment for production workers.
18. Direct the day-to-day activities of the Quality Technician(s).
19. Work with Plant Manager to provide direction to and ensure the personal and professional development of the Laboratory Manager and the Program Manager.
20. Collaborate with the Laboratory Manager to develop Donsco’s in-house quality labs and staff so that they can effectively conduct and manage sand and metallurgical tests including metal certification and test bar prep, analysis, and storage.
21. Support the Supply Chain Manager and Plant Manager to facilitate effective supplier selection, certification, and re-certification.
22. Perform other duties and manage special projects as assigned by the Plant Manager.

ESSENTIAL JOB REQUIREMENTS (BACKGROUND/SKILL/TRAINING):
1. Bachelor's Degree in Quality Management, Manufacturing / Industrial Engineering, or Metallurgical Engineering.
2. A minimum of five years in quality management in an iron foundry.
3. Deep understanding of casting defects and their causes.
4. Demonstrates knowledge of advanced quality management and improvement tools and techniques including APQP, cost of quality, TQM, SPC, root cause analysis, corrective actions, etc.
5. Strong knowledge of the technology and information systems required to be effective.
6. Strong training and employee development skills.
7. Ability to engage well with internal and external customers to accomplish goals.
8. Strong organizational and planning skills, problem-solving skills, and oral and written communication skills.
9. Team-oriented, ethical, and trustworthy.
10. Flexible and able to adapt to and embrace change.
11. Detail-oriented and results-driven. Able to make decisions and act responsibly.

PHYSICAL DEMANDS OF THE JOB:
Physical Requirements Required Frequency
Standing X 100%
Walking X 100%
Pushing/Pulling X 100%
Grabbing/Reaching X 100%
Lifting X 25%

WORKING ENVIRONMENT:
The work is primarily performed in a non-temperature controlled; smoke-free manufacturing environment. Noise level is moderate to loud. The individual is exposed to extremes in temperature on a regular basis. Employee is required to wear designated PPE at all times while in the plant. Work may be performed near equipment with moving parts or require use of some chemicals and resigns.