Quality Assurance Manager

SUMMARY


Plans, coordinates, directs, and executes activities concerned with development, application, and maintenance of quality standards for products, production processes, inspection and laboratory testing. Ensures compliance with customer specifications, industry standards, and the company's Quality Management System while maintaining the integrity of products manufactured at Fontana or Chino sites. Oversees quality assurance, metallurgical testing, process monitoring, supplier and equipment qualification, and continuous improvement initiatives. Carries out supervisory responsibilities in accordance with company policies and applicable laws.


ESSENTIAL DUTIES AND RESPONSIBILITIES

• Responsible for overall integrity of Fontana and Chino products.
• Plans, directs, supervises and coordinates the activities of employees in Quality and metallurgy departments
• Identifies areas of improvement and drafts annual departmental objectives to improve safety and operational efficiency as well as setting targets for cost reduction
• Confers and cooperates with other management personnel in formulating administrative and operational procedures that support the quality standards.
• Works with Sales and Production Departments to make necessary changes required by customers
• Responsible for customer satisfaction related to product quality; responds to customer claims and provides technical support.
• Responsible for the technical and quality portion of customer contract review (technical specs review for feasibility, applicability and implementation).
• Develops/monitors homogenization and casting practices to ensure product consistency as it relates to quality performance and meeting customer requirements.
• Develops/monitors production and inspection processes to meet customer and applicable industry technical specifications/requirements.
• Monitors and adjusts the production process using statistical process control through analysis of processing parameters and metallurgical testing results to ensure that all requirements, both internal and external, are met.
• Leads periodical and scheduled metallurgical testing to ensure customer quality requirements, to determine causes of non-conforming product and/or for continuous improvement for quality and production efficiency.
• Compiles and analyzes test information to determine product failures or improvements.
• Responsible for qualification and quality performance monitoring of smelting, casting and homogenizing equipment (including applicable HO and SAT surveys).
• Responsible for qualification and quality performance monitoring of applicable raw materials, key equipment/instrument/tooling and suppliers (products and services - e.g. calibration services).
• Responsible for quality control and UT inspection systems.
• Ensures reliability and consistency of all testing equipment/instruments (including but not limited to standardization/calibration processes, proper report documentation and traceability)
• Monitors and continually improves Gage R&R for inspection processes.
• Responsible for lab safety, lab cleanliness and sample storage and traceability for both QA lab and metallurgy lab.
• Documents, implements and maintains written procedures as needed for standardization of processes.
• Responsible for maintaining up to date documented procedures, work instructions, inspection forms for their department.
• Ensures proper filing and documentation (location, accessibility and retention period) for all product/inspection/production reports that impact quality and/or product integrity.
• Prepares reports of production recoveries and quality performance for presentation to upper management as necessary
• Ensures proper compliance of all safety and company rules and regulations
• Participates in project teams and other management committees as necessary
• Performs other duties as assigned by Management

QUALIFICATIONS AND EXPERIENCE

• Bachelor of Science degree in Metallurgical, Mechanical or related field
• Five years experience in aluminum casting processes or management level metallurgy; or equivalent combination of education and experience equal to 10 years in a related field.
• Experience in latest ISO Standard for quality management systems.
• Proficient in problem solving techniques, including root cause analysis, process mapping, corrective and preventive action.
• Near Vision: Jaegar (Type 1 or equivalent)
• Color Vision: Must be able to distinguish and differentiate between colors used during the product acceptance/certification process.
• Preferred:
  • Experience with Ultrasonic Testing (AMS-STD-2154 standard)
  • Experience with OES Spectrometry method ASTM E1251-17a
  • Experience with ASTM E716-16 and AMS 2355M for sampling processes
  • Proficient in Lean Manufacturing and 5S principles.
  • Six Sigma Green Belt.
• Plus:
  • Familiarity with Forging processes
  • Familiarity with ASTM E112 for determining grain size.
  • Familiarity with ASTM E1417 for liquid penetrant testing
  • Familiarity with metallographic etching practices such as Keller's or Poulton.

• SKILLS AND ABILITIES
• Ability to read, analyze, and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to write reports, business correspondence, and procedure manuals. Ability to effectively present information and respond to questions from groups of managers, clients, customers, and the general public. Ability to use multiple software programs.
• Ability to work with mathematical concepts such as probability and statistical Interference, and fundamentals of plane and solid geometry and trigonometry. Ability to apply concepts such as fractions, percentages, ratios, and proportions to practical situations.
• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exits. Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.
• Diversified and involves some choice of action within limits defined by standards/instructions. Under supervision.

PHYSICAL DEMANDS

While performing normal duties, the employee is regularly required to stand, walk, climb or balance, stoop, kneel, crouch, or crawl. The employee must occasionally lift and/or move up to 25 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus. Reasonable accommodations will be made for employees with disabilities as required by law.

WORK ENVIRONMENT

The employee may be exposed to moving mechanical parts and outside weather conditions. The employee is occasionally exposed to wet and/or humid conditions; high, precarious places; fumes or airborne particles; and extreme heat. Noise level is usually loud requiring hearing protection in some areas. Reasonable accommodations will be made for employees with disabilities as required by law.