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Quality Engineer

2 months ago

Elkhart, United States Morgan Advanced Materials Full time

Overview:

Morgan Advanced Materials is a business rich in history and innovation. Founded in the UK in 1856, we have grown into a global organisation with 70 sites in 18 countries. Our model to serve our customers where they need us has led to a diversified product range using our unparalleled expertise in ceramic and carbon materials, which we exploit to solve difficult problems for our customers across a diverse range of markets.

We are a purpose driven organisation. Our purpose is to use advanced materials to make the world more sustainable and to improve the quality of life. We deliver on that purpose through the products that we make, and the way that we make them.

The Thermal Ceramics division designs, manufactures and installs a broad range of thermal insulation products that significantly reduce energy consumption and emissions in a variety of high temperature processing applications. Our product offering is extensive and covers application needs from Industrial to Commercial markets.

Key Figures: Revenue 1,114.7m (2023), ~8,500 employees, manufacturing in 20+ countries, and a global customer portfolio. A UK PLC with head office located in Windsor, Berkshire UK. Listed on London Stock Exchange; Member of the FTSE 250 Index.

Responsibilities:

Definition:

Reports to Quality Manager and assists production and other functional areas to produce a quality product that meets customer specifications and adheres to AS9100 requirements.

Purpose:

Responsible for ensuring that the products produced meet quality standards required to minimize quality costs and maximize customer satisfaction whilst ensuring that procedures and processes are adhered to. Ensure incoming materials meet required quality standards. Responsible for identifying and raising quality issues and for speedily resolving them to ensure zero impact to the customer. Support new product introductions to ensure the robustness of product builds. Work in a team environment to develop and implement best practices that emphasize defect prevention, reduction in variation and waste and provide for continuous improvements in meeting all customer requirements. Manage the customer specific requirements and offer technical support. Responsible for multiple highly complex major projects requiring innovative original solutions where results are key to successful completion of major projects. Work mostly independently with minimal supervision and work is reviewed at project milestones and/or on completion by Senior Management.

Key Responsibilities:

General and Task Management

  • Manage all quality-related issues within the manufacturing team (e.g., internal, supplier, customer, and customer warranty)
  • Identify root cause and instigate permanent corrective actions for product quality issues.
  • Work with internal and external stakeholders to resolve quality issues that arise as quickly and efficiently as possible to prevent compromising quality and safety standards.
  • Carry out product and process auditing.
  • Ensure all PPAP documentation is implemented effectively and maintained. Including but not limited to Process Flow, Control Plan, PFMEA, MSA, Capability Study.
  • Monitor and report on quality-related key performance indicators including scrap monitoring, rework levels.
  • Stop production in the event of manufacture of unacceptable goods/processes.
  • Ensure compliance and assist with adherence to the Quality Management system (AS9100)
  • Help write and verify product test procedures for accuracy.
  • Undertake special projects as required. (e.g., FI team, help other teams identify root cause, 6S.
  • Assist with training of quality awareness.
  • Report on Key Performance Indicators (KPIs) in order to adhere to process and prevent occurrence of any non-conformity relating to product, process or system.
  • Assist with first off sample approvals.
  • Promote the use of customer preferred techniques for continuous improvement such as Six-Sigma, Poka-Yoke (Error Proofing), and Measurement System Analysis.
  • Participate in cross-functional teams in changes related to current products in meeting customer requirements.
  • Participate in the development and refinement of Process FMEAs (Failure Mode and Effects Analysis)
  • Manage Key Performance Indicators (KPIs)
  • Manage and coordinate customer PPM (Parts per Million), supplier PPM, supplier problem solving on time, cost recovery and supplier warranty indicators.
  • Manage quality audits and internal audits.
  • Keep up with current and developing manufacturing and engineering trends that concern product quality.
  • Contribute to continuous improvement activities.
  • Support process improvement activities
  • Write reports and present progress at project meetings and to clients.
  • Achieve goals within budget.
  • Conduct benchmarking studies to determine best practices and future trends.
  • Plan projects or subtasks so they may be tracked and presented.
  • Attend various meetings and action/communicate instructions.
  • Produce written reports and make presentations.
  • Undertake continuous training and development of other team members.
  • Perform root cause analysis and resolve problems.
  • Independently determine approach and assigned tasks.

People Management

  • Support groups of technicians and engineers
  • Provide guidance to other team members.
  • Train both team and broader organization members

Relationship Management

Support regular inspection meetings with representatives from appropriate departments to establish an action plan for improving build quality.

  • Communicate efficiently throughout the shop floor and with own and customers management.
  • Communicate with other departments, customers, suppliers and other service providers.

Self-Management

  • Comply with the Health, Safety and Environmental Policies
  • Assertive and welcomes change.
  • Engages interest and participation of others and has a collaborative approach to working with others.
  • Proactively contributes to the team.
  • Self-aware and forthright.
  • Is resilient, optimistic, and open to change.
  • Shows moral courage, openness, and honesty in all dealings.
Qualifications:
  • Bachelors Degree, preferably in Engineering
  • Minimum of 1 year of experience in a manufacturing setting
  • Exercise substantial initiative/judgement in work methods and interpreting goals
  • Work independently and is reviewed infrequently with minimal supervision.
  • Self-supervising within the guidance and expectations of divisional management
  • Knowledge of quality systems and measurement.
  • Strong knowledge of Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP), Failure Mode and Effect Analysis (FMEA)
  • Lean Manufacturing knowledge
  • Familiarity with Quality Management Systems (QMSs), in particular AS9100 based. Familiarity with AS13100 is a bonus.
  • Experience in a manufacturing environment and working with other Production and supporting functions. Comprehension of product and process flow from Receiving to Shipping, traceability, stocking and inventory (raw materials, work-in-process, and finished goods). Comprehension for distinction between documents and records and familiarity with routers, work orders, bills of material, and other supporting Production paperwork
  • Experience writing work instructions to abide by AS9100 guidelines.
  • Experience with Computer Aided Design (CAD).
  • Ability to analyze risk, identify opportunities and correct or contain.
  • Understanding of ISO14001 and Health and Safety practices
  • Understanding of engineering drawings and manufacturing processes
  • Ability to work in a diverse and dynamic environment.
  • Planning and prioritizing activities
  • Good communication and interpersonal skills
  • Negotiation skills
  • Ability to present data effectively.
  • Problem-solving skills
  • Team working skills.
  • Analytical skills
  • Understanding of cost and financial impacts
  • This position requires use of information which is subject to the International Traffic in Arms Regulations (ITAR), Export Administration Regulations (EAR), and Nuclear Regulatory Commission (NRC). Individual must be a:
    o Citizen of the United States, or
    o Permanent resident alien of the United States, or
    o Protected individual as defined by 8 U.S.C. 1324b(a)(3) as defined by 22CFR120.15 ind-1