Quality Engineer

About the Role:

This role will provide analysis, direction and coordination for assigned aspects of Haynes' Quality System to minimize risks and implement/document effective quality controls. These aspects include technical aspects in support of AS9100, Nadcap and customer specific Quality requirements. This role will also work in conjunction with Mfg. Engineering and Manufacturing/Production teams to develop effective Process/Quality Control and Improvement programs to reduce off-quality costs and mitigate risks.

Qualifications:

Education: B.S. (R) or advanced degree in technical discipline, preferably in Metallurgy, Materials Science, or Chemical Engineering; Other degrees may be considered depending on career experiences.

Experience: 3-5+ years w/ B.S. in Engineering or 1-3+ years w/ M.S. or higher; experience in Manufacturing and/or Quality Assurance is preferable, esp. related to aerospace metallic materials or other quality system-critical environments.

Areas of Knowledge: Quality systems and functions (R), preferably related to ISO9001/AS9100, Nadcap, PFMEA, PPAP, Six sigma/Lean, auditing, standard materials specifications (AMS, ASTM, ASME, etc.) and Statistical Process Control (SPC) (All P); Knowledge of thermo-mechanical and/or melting processing and/or physical metallurgy of Ni- and Co base alloys (P); Manufacturing processes/equipment involved with the production of major Haynes wrought product forms (P).

Skills: Organization, Planning & Project Management, Technical Specification Requirements synthesis, Technical Communication (written and oral), Observational and Analytical skills (All R); Computer skills - Office suite, Minitab, AX/D365, Shopfloor and other Haynes internal systems, etc. (P).

Role Responsibilities:

• Utilize available Quality tools, such as PFMEA, DMAIC, Green/Black Belt programs, Cause-and-Effect diagrams, Pareto charts, Flowcharting, and other Risk Analysis methods to assess potential problems within assigned area of responsibility in need of corrective action and/or investment. Coordinate analyses with Sales & Marketing to ensure customer expectations are fully aligned with quality plans, routings, and production results.
• Analyze processes and product quality for assigned areas and coordinate with Manufacturing Engineering, Production, Maintenance/TPM group, and Plant Engineering to identify process/equipment/procedural issues that impact overall quality and yield and identify means of remediating issues.
• Quantify identified issues to develop appropriate and standardized KPI’s/Quality Metrics/Performance tracking and reporting for individual processes and/or production areas to demonstrate effectiveness of methods and to support Quality reporting for corporate goals and compliance.
• Review SOP & QCI documents vis-à-vis identified process risks and issues for each primary process route to ensure that a Quality control plan provides actionable requirements for effective production of specified products.
  • Support development of initial and refresher training plans (departmental and/or individual) to ensure personnel receive the proper safety, quality system & required job specific instructions to achieve control goals.
  • Document key Quality Systems procedures for all hourly/salary personnel that ensure adequate and appropriate transfer of knowledge and key performance steps for all Haynes employees in assigned or related areas.
  • Coordinate as required to acquire instruments/sensors/equipment or other hardware/software to demonstrate effective process controls.
• Ensure effective, continuous efforts to coordinate with colleagues and key cross-functional groups to improve process capabilities & procedures consistent with corporate goals and directions, including support for new equipment.
• Regularly review quality reports, such as daily and monthly scrap & rework summaries, Mfg. Engineering activity reports, Sales reports, NCRs/Customer complaints to identify potential process control issues. As needed, support investigation of customer complaints, provide for root cause analysis and corrective actions and incorporate findings into SOP’s and QCI’s. Support Sales & Marketing with technical and quality system requirements, as needed.
• Coordinate with Manager to develop process quality control and improvement plans and priorities to meet customer expectations.