Quality Control Inspector

Quality Control Inspector

The Quality Control Inspector ensures that incoming, in process, and finished parts are within all required specifications per drawings and work instructions. It is the Quality Control Inspector's responsibility to implement good documentation practices (GDP) and proper material identification, preventing nonconforming material from continuing through the process without proper approval, to ensure that the customer gets parts that function properly every time.

Job Category: Hourly

Department: Quality Control

Reports To: Quality Group Leader

Hours: 7:00am – 4:00pm, additional hours as needed.

Responsibilities

1. Safety

2. General Quality and Housekeeping

3. Incoming Material Inspection

4. In Process Inspection

5. Finished Product Inspection

6. Inventory Management

7. Continuous Improvement

8. Training and Personal Development

9. Culture

KRA-RELATED TASKS AND ACCOUNTABILITIES

1. Safety

· Tasks and Activities

o Wears PPE as outlined in the Sonny's PPE Policy

o Identifies unsafe work behaviors and reports them to the Safety Manager

o Identifies unsafe work conditions and reports them to the Safety Manager

o Attends monthly safety trainings

o Wears uniform as required by policy and displays name badge at all times

o Maintains an organized and safe work area

o Lifts using proper technique

o Keeps all walkways, emergency exits, and panels free from obstruction in accordance with Sonny's requirements and all local, state, and national safety codes

o Obtains LPG sit-down forklift license within first 3 months of employment and maintains license thereafter

· Accountability (Output)

o No lost time accidents (Time Span: 1 day)

2. General Quality and Housekeeping

· Tasks and Activities

o Performs area specific internal quality audits

o Performs area specific 5S audits

o Performs random in-process audits in designated areas

o Performs first piece inspection audits for team members as required

o Maintains and stores inspection equipment appropriately

o Verifies presence of calibration sticker before using measurement device

o Notifies manager of equipment with past due calibration

o Notifies manager of calibrated items that need attention

o Reviews and provides feedback on procedures, policies, and processes

o Applies proper sampling methods (AQL) managing risk and cycle time

o Interprets and inspects mechanical drawings (GD&T literate)

o Maintains all inspections records or other required documentation

o Coordinates, implements, and documents containment actions

o Actively supports conducting root cause investigations

· Accountability (Output)

o Perform minimum of one audit per month. The audit report should be delivered to the manager and include scope, opportunities for improvement, and nonconformances. (Time Span: 1 month)

o Maintain quality equipment log daily with quantity, location, and calibration information (Time Span: 1 day)

3. Incoming Material Inspection

· Tasks and Activities

o Verifies quantity delivered to the purchase order

o Communicate issues, concerns, requirements to truck driver

o Notifies production supervisor of trucks that need to be unloaded by a material handler

o Processes receipts in ERP system

o Processes delivery documentation including adding notes for potential damage, etc.

o Unloads trucks as required

o Performs final signoff / approval to release incoming material to production

o Notifies manager of nonconforming product and any systemic issues that are noticed

o Applies strong process discipline to material identification in particular with quarantined nonconforming material (red tag)

o Quarantines nonconforming material physically and in the ERP system (SAP)

o Communicates expeditiously with purchasing to ensure returns, reorders, etc. are processed as quickly as possible

o Update vendor issues list daily

· Accountability (Output)

o Process all required daily incoming material inspections and SAP transactions (Time Span: 1 day)

o Ensure correct material identification for all incoming PARTs. Ensure quarantine is controlled. (Time Span: 1 day)

o Nonconforming material is communicated to manager and purchasing same day as discovered. Include all details required to submit a SCAR if needed: PO Number, PART Number, Specification, Result, Quantity, etc. (Time Span: 1 day)

4. In-Process Inspection

· Tasks and Activities

o Performs in-process inspection plans as required with appropriate sampling (AQL)

o Performs verification of machine setup prior to running first piece

o Releases in-process materials if first piece inspection passes

o Performs inspection and is responsible for release of production orders to next production area

o Communicates with production supervisors and prioritizes inspections accordingly with rush / urgent jobs first

o Perform spot audits and document continuous improvement opportunities when other tasks are complete

· Accountability (Output)

o Performs all daily first piece inspections (Time Span: 1 day)

o Review all daily documentation (executed production orders, inspection forms, etc.) for good documentation practices (GDP) and ensure proper storage (Time Span: 1 day)

5. Finished Product Inspection

· Tasks and Activities

o Completes product audit checklist for finished goods items

o Releases finished goods items for shipping / storage

o Maintains all finished goods release / certification documentation

· Accountability (Output)

o Completes all required daily finished goods releases (Time Span: 1 day)

6. Continuous Improvement

· Tasks and Activities

o Acts as primary point of contact; identifies challenges, inefficiencies, or areas of opportunity and communicates them to the manager

o Proposes solutions to address identified challenges, inefficiencies, and areas of opportunity

o Participates and provides feedback and ideas in problem solving meetings as required

o Implements process improvements according to plan developed by the manager

o Attends and provides feedback in after-action reviews following the implementation of process improvement projects

o Acts as primary point of contact/project manager for improvement projects as designated by manager

o Develops timelines for project plan and execution in collaboration with manager and production team

o Manages projects and timelines up to 6 months in length

· Accountability (Output)

o Leads team to implement process improvement plans as assigned by manager (Time Span: Up to 6 months)

o Provides candid, honest, constructive feedback during brainstorming and after-action review meetings (Time Span: Up to 3 months)

o Creates, manages, and updates timeline for all improvement projects in designated area to keep projects on track (Time Span: Up to 6 months)

7. Inventory Management

· Tasks and Activities

o Performs and verifies transactions in ERP system (SAP) accurately

o Spot audits material identification in all production areas

o Spot audits physical quantities vs SAP quantities

o Periodically reviews bin locations for accuracy and location (set in place)

o Assesses and communicates storage bin size adequacy or lack thereof

· Accountability (Output)

o Complete a minimum of one (1) spot audit daily (Time Span: 1 day)

8. Training and Personal Development

· Tasks and Activities

o Completes annual self-evaluation review on time

o During annual review, clearly articulates goals for upcoming quarter to manger

o Completes goals