Quality Engineer (Navi Mumbai)

Job Title - Quality Engineer 

Reports to - Country Manager

Location - Navi Mumbai

Consistent with NOV’s FMS corporate plant standards and department objectives. Working within the Quality team, the Quality Engineer will be responsible for driving down the cost of non-quality, and continually reducing customer escapes through applying appropriate Quality and Continual Improvement tools & techniques. The Quality Engineer will be assigned to the Assembly Shop primarily, with other departments allocated based on demand, whereby the Quality Engineer’s focus will be aligned together with the relevant department leader and team. The Quality team is a Support function to the wider NOV business, as a result, the Quality Engineer will foster and develop relationships both within assigned departments, and as required by the business, conducive to offering the support needed.

DUTIES & RESPONSIBILITIES:

• Perform all incoming, process & final inspection activities.
• Verification of raw material and inspection of machined, fabricated components & bought-out items.
• Review and approval of related quality documents during inward inspection.
• Proven track record of hands-on experience in physical inspection of machined and fabricated parts
• Conducting a physical inspection of parts at the vendor end as per need.
• Ensure products meet the organization's and customers' quality and product integrity requirements.
• Review of final documentation as per project requirements.
• Monitor & assist on ongoing Quality Performance of approved suppliers.
• Maintaining Rejection & Rework record.
• Review of Rejection/Rework data and finalize the disposition.
• Identify root causes of problems in the manufacturing process; recommends and/or implements corrective measures.
• Analyses data to identify trends in product quality or defects with the goal of mitigating and preventing recurrence and future defects.
• Communicate to vendors for all non-conformities and recording vendor CAPA.
• Do root cause analysis using different tools such as 5 Why’s, Ishikawa Fishbone Diagram, 8D problem solving, etc.
• Conducting new supplier assessment & approval for business.
• Periodic re-qualification audits of existing vendors.
• Conducting first article inspection and approval for bulk production.
• Customer complaint handling and analysis.
• Provide quarterly inspection data and quality assurance reports to senior management.
• Co-ordination with the cross-functional teams.
• Where assigned to a department (specific):

1. be the focal point for all quality issues and resultant successful remedy.
2. lead and project manage agreed improvement activities geared towards Cost Quality & Schedule Adherence
3. manage the material review board (MRB) activity and subsequent Root Cause Analysis (RCA) and Corrective Action (CA) predominantly within the assigned department/s, as required by the business.

• Map existing processes using suitable tools (Value Stream Mapping/ SIPOC) to understand Suppliers, Inputs, Outputs, & Customers
• Develop processes to facilitate risk reduction and a lean ‘way of working’.
• Creation and successful deployment of Procedures, Standard Operating Procedures (SOPs) and Work Instructions (WIs) in support of the assigned department and as required by the business.
• Ensure adherence with internal and external customer/ regulatory requirements. 
• Drive improvement activity within the assigned department/s, and as required by the business.
• Contribute and participate in internal and external audits as required.
• Development and deployment of key quality tools such as p/d FMEA, Measurement Systems Analysis (MSA), 8D Problem Solving, 5 Whys, Process Papping, Statistical Process Control (SPC), and the support of others in the use therein.
• Represent the quality function during ad-hoc and/ or routine reviews. 
• Measure and report performance KPIs as required:
  1. Non-conformance & CAPA quantity and trends
  2. Internal audit compliance
  3. Improvement activities through ‘Fix Something’ & Six Sigma initiatives 
• Compile quality-specific reports and/ or technical documentation in support of the business

SKILLS & EXPERIENCE REQUIRED

Strategic

• Quality and Continual Improvement tools such as (but not limited to): p/d FMEA, AS9145 (APQP/ PPAP), 5’S, Lean, MSA & Gauge R&R, 8D, 5 Why’s, Process Mapping, & SPC (key)
• Understand technical drawings including GD&T (Key)
• Auditing experience (Nice to have)
• Exposure to industry 4.0, to include (Nice to have):
  1. Introducing the digital ‘smart’ operation/ roadmap
  2. Introducing semi-autonomous & mobile platforms 
  3. Reducing human interaction 
• Minitab user (Nice to have)

Operating

• Adept at exercising good judgement (sometimes with incomplete information) whilst being constrained by tight deadlines.
• Be willing to provide colleagues with the information they need to complete their tasks and eliminate roadblocks.
• Be quick to identify critical information and respond appropriately.
• Able to mentor and develop direct reports through formal processes and exposure to new tasks.
• Able to define, set in place, monitor, and measure effective processes.
• Able to apportion time effectively to complete tasks.

Confidence

• Can be counted on to take personal responsibility in challenging situations and be willing to engage in disputes to settle them equitably.
• Able to comprehensively define roles, identify talent and effectively staff in accordance with business structural requirements.

Energy

• Will be energized by challenges and drawn towards opportunities.
• Will be able to sustain the team’s direction and effort towards the achievement of long-term goals.

Organizational

• Confident and professional when representing the company in person and in writing.
• Aspiring and keen to advance within the organization.
• Understanding of the nature of large organizations and being able to leverage understanding to the best effect.

Personal & Interpersonal

• A strong sense of customer focus (internal/external)
• Approachable, with a facilitating demeanor, and an ‘I’ll do it mentality. 
• Ability to work and relate effectively with both executives and operators on the floor to drive a teamwork mentality and communicate goals and         progress towards them.
• A candid team player who collaborates with peers to solve problems.
• Committed to self-improvement and development through the role in order to achieve career goals.
• Able to conceive of a compelling vision for the business and imbue others with the same.

QUALIFICATIONS & EXPERIENCE

• Six Sigma green belt or higher (Key)
• Mechanical engineering background
• At least 5 years’ experience within a similar quality engineering role (key)
• Understanding, and practical use of the following tools/ techniques: (key)
• FMEA
• APQP/PPAP
• 5’S
• MSA including Type 1 & GRR gauge studies.
• 8D problem solving.
• 5 Why’s
• Process mapping (VSM or SIPOC)
• Process Control (SPC), Cp & Cpk etc
• Computer literacy (including good command of Microsoft Excel, Word and Outlook)
• Lean Manufacturing knowledge
• ISO9001 Quality Management

Bonus Points for:

• Inspection experience (1st principles and/ or automated inspection)
• Six Sigma Black Belt
• ISO9001 internal/ lead auditing
• Precision engineering background
• Exposure and knowledge of JDE ERP systems 
• Understanding, and practical use of the following tools/ techniques: 
• Fault tree diagram
• Causal factor map
• Control charts
• Solution selection matrix
• 5W2H Problem matrix
• ISO9001 auditing experience
• Minitab user
• Knowledge of CMM & VICI vision systems, and the data created.
• QC Calc SPC software
• Industry 4.0
• Internet of things! (IoT)
• ‘Big Data’
• Automation
• Data Management