Quality Engineer

• Responsible for production process quality and product outcome using planning, measurement-based control, audit procedures and corrective action methodologies.

• Supervision and coordination of Quality Technician in delivery of production quality.

• ISO 9001:2015 internal and supplier compliance audits.

• 8D, NPI/FAI, FMEA, Control Plan, and other related quality procedures delivery.

• Working with other departments to harmonize Quality related objectives.

• Problem investigation and corrective action implementation.

• Maintain the Quality System via annually scheduled audits.

• Determining, negotiating, and agreeing on in-house quality procedures, standards, and specifications
• Root cause analysis
• Monitor manufacturing processes comply with standards at both national and international level.
• Writing technical reports, generating quality reports and customer charters.
• Determining daily focus areas based on failure reports to drive continuous process improvements.
• Conducting daily failure investigations and generation of reports and related communication.
• Prepares quality documentation and reports by collecting, analyzing, and summarizing information and
  trends including failed processes, stability studies, recalls, corrective actions, 8D reports and re-validation.

• Prepare quality instructions for all CBI Products and accessories
• Prepare Inspection instructions on the Infinity QS system

• Conduct capabilities on new and existing products and/or processes.

• Gauge capability study on new checking gauges when required

• Assist in determining and advising on suitability of such gauges
• Determine best method/process to achieve highest quality in product performance
• Extend a testing process to meet technical specification and capabilities
• Execute and carry out audits to identify problems related to manufacturing processes
• Carry out technical investigation for process problems
• Ensure compliance to ISO, SABS and international standards
• Enforce strict adherence to all quality procedures or processes throughout
• Ensure quality instructions and processes follow ISO, SABS and international standards
• Ensure statistical data is available for process analysis
• Perform process capability studies and R&R studies
• Control of reports and specifications thereof
• Quality audit test reports and documentation
• Initiate and maintain all process drawings and inspection instructions for designated products
• Analyze error and exception reports
• Maintain an accurate record of exceptions and errors
• Ensure confidentiality of information and tests
• Ensure that manufacturing departments implement inspection instructions
• Ensure correct process drawings and amendments are available
• Follow up on “out of control conditions”
• Representing quality on core team
• Offer advice on evaluated tests and processes
• Discuss concerns related to product, process, assembly or quality instructions
• Conduct investigation related to aforesaid concerns
• Quality audits as required
• Liaise with QA executive on technical matters
• Prepare and write quality instructions and compile process inspection aids
• Calculate tolerances and variables in design or component
• Determine best method/solution required to achieve the right results
• Ensure testing and/or connecting products is done in accordance with safety procedure
• Maintain safety in all the testing areas, at all times
• Maintain an electronic filing system on and generate reports from them
• Prepare and collate training material specifically related to Quality

• Provide Quality related training as and when required

• Identify the level of training required in line with the educational/skills level of the trainees

• • Reduce the cost of defective product in the company

  • Ensure Quality Control Plan adherence and up-to-date APQP documents
  • Monitor compliance with C.I. initiatives like DPS, QLI, Gatekeepers and Lean Manufacturing
  • Effective resolution of technical queries and control of product and processes under deviation (code red)
  • Stock levels under quarantine(location H.OL.D and reworks) is at a minimum and proper control is exercised in accordance with Control of Non-conforming product practices
  • Conduct and Maintain APQP: FMEA; Quality Control plan; PPAP and PSW
  • Ensure compliance to APQP (especially QCP) by regular review, updates and monitoring
  • Conduct ISIR approvals and other PPAP functions
  • Responsible for Product Yield: Defect Management(Closing; Actions; Scrap; Code Red; Analysis etc.), SPC, CCR investigation and correction and inspection
  • Monitor and guide all activities related to QLI and gatekeeper functions
  • Responsible for Controlled Rework as per Rework instructions
  • Ensure periodical reports are compiled and submitted
  • ISO 9001:2015 and ISO 14001:2015
  • ISO/TS 16949:2009
  • 6 Sigma

   

  Achievements

  • Raised R 56 352.48  CAPEX for Red, Yellow, Green bin liners and  implemented parts segregation in Donaldson Epping plant Cape Town within compliance of  TS16949 Quality Management System.

  • SPC on 3 lines (Breather Paint Inspection Station, Breather Leak Testing Station, Pre-Treatment Plant)

  • Performed tests for  new equipment qualification and approved new Radial Seal machine commissioned for Donaldson Epping plant Cape Town

  • Reduced internal quality scrap cost of Element Filters from R857 050.62 to R392 010.63 for F14 (fiscal year)

  • Reduced internal quality scrap cost of Element Filters from R392 010.63 to R205 863.74 for F15 (fiscal year)

    • GM Supplier Quality Excellence Award

• Develop and maintain logic control programs for Wonderware SCADA system to monitor and control all plant processes.
• Troubleshoot and resolve any issues related to logic control programs.
• Optimize program performance for improved efficiency and accuracy.
• Develop and maintain software applications using Archestra/In Touch platforms using WindowMaker.
• Collaborate with cross-functional teams to design and develop new software applications.
• Design and maintain databases to store production data and other relevant information using Microsoft SQL Server Management Studio.
• Develop queries to extract and analyze data to support continuous improvement initiatives.
• Conduct database backups and ensure data is secure.
• Identify areas for improvement in plant processes and lead continuous improvement projects to eliminate waste and increase efficiency.
• Use lean manufacturing principles to streamline processes and reduce lead times.
• Collaborate with cross-functional teams to implement changes and measure results.
• Create and maintain site layout plans and technical drawings for plant processes.
• Use AutoCAD software to design and modify layout plans and drawings.
• Ensure drawings are accurate and up to date.
• Analyze plant processes to identify waste and inefficiencies.
• Use value stream mapping techniques to determine areas for improvement.
• Analyze workstation load and identify bottlenecks in processes.
• Use line balancing techniques to optimize workstation assignments and reduce lead times.
• Analyze labor costs and allocate resources effectively to improve efficiency and reduce costs.

Achievements

• Introduced and implemented SPC for Kallstrom Leveling Machine.
• Designed Erward Effluent Plant on Archestra/In Touch – WindowMaker for First National Battery Wonderware SCADA.

• Implement process improvements and lean manufacturing techniques to increase efficiency and reduce waste.
• Analyze and optimize operations using time-study and method-study techniques.
• Utilize AutoCAD to create site layout plans and technical drawings to improve site organization.
• Utilize value stream mapping to identify and eliminate waste, resulting in reduced processing and lead times.
• Implement one-piece flow to increase efficiency and reduce labor costs.
• Balance workstations to eliminate bottlenecks and optimize labor costs.
• Develop and update work instructions for manufacturing processes.
• Monitor and improve process efficiency to ensure smooth operations.
• Optimize warehouse storage and inventory management using stock arrangement and storage utilization plans.
• Generate Non-Conformance Reports using Lotus Software.
• Utilize JD Edwards Software for effective MRP planning and inventory management.
• Assess OEE (Overall Equipment Effectiveness).
• Execute red tagging procedures to ensure safe and efficient operations.

Achievements

• Improved processes in the battery breaking department.
• Provided recommendations on implementing a new storage system for warehouses to minimize excessive travelling time.