Process & Quality Assurance Engineer - Australian Company

The incumbent is responsible for managing all aspects of product introductions (new or modified) at Rheem to achieve SQCPD project deliverables e.g. Safety, wellbeing, health and environment, Quality, Cost, Delivery on time, and People motivated to support new Product, Continuous Improvement Programs for Production, and other Projects assigned by the Supervisor or General Director.
Specific responsibilities are as follows:
o Process
• Establish local Project Teams and conduct project meetings.
• Lead the project teams, assign tasks to team members and drive team members to complete assigned tasks.
• "Poke Yoke" and OEE monitoring to improve plant efficiency and improved product quality.
• Manage the following activities through the project teams.
o Identify, provide feasibility studies, and implement design improvements to suit manufacturing processes, or for the introduction of new plant, equipment, and tooling.
o Develop new and existing manufacturing processes.
o Liaise with the Service personnel in relation to field problems and reviewing the product/process with the aim of eliminating the manufacturing defects/problems.
o Participate in Failure Mode Effects Analysis, FMEA
o Participate in Design for Manufacture Effects Analysis, DFMEA
o Define, improve and document Process Flow Charts, Process Control Plans
o Develop proposals through to implementation for machine factory layouts for new projects and provide a continuous improvement for existing manufacturing cells.
o Prepare tooling & equipment specifications (RFQs) and obtain quotations.
o Become an active member in managing new project costs and capital/expense spends within allocated budget and on time.
o Purchase, install and commission new tooling and equipment.
o Leader in TT&T, CQV, SAT, FAT approval projects through to Certificate of Practical Completion, including Project Closeout.
o Conduct production trials and pilot runs and a key member to ensure PPAS/PPAP records are compliant prior to production commencement.
o Provide the necessary plant standard operating procedures and work instructions, including preparation and maintenance of First of Check Sheets, Daily Check Sheets, and Preventative Maintenance or condition monitoring activities for all new processes, projects and the continuous improvement of existing process and machine work centres.
o Train personnel in the correct assembly/operating procedures on existing/new equipment.
o Ensuring all material, component and product approvals are obtained.
o Conduct SHE Risk Assessments on production machinery and processes. Develop and implement hazard control measures.
o Maintain the Quality System ISO 9001 and report to management on necessary improvements.
o To ensure that safe working and handling practices are followed and provide input into ways of improving OH&S of all personnel.
o Become an active member in participating in TIMWOODS waste elimination in manufacturing.
o Lead quality 8D improvement programs through areas such as, but not limited to, Safety, Quality, Cost/Waste elimination, and HPU/productivity improvements.
o Prepare and issue project team minutes and Action Plans
o Communicate project status and critical actions within the Rheem operation.
o Liase with all departments associated with the planning, implementation, and introduction of new products and/or production techniques.
o Manage project expenditure and maintain accurate expenditure records.
o Maintain an accurate, current operations timeline.
o Maintain accurate project records and documentation.
o Quality
Ensure the adequacy and management of process documentation required to support quality output from our manufacturing and assembly operations. Specifically:
• Process Flows,
• Product Quality Plans (PQP),
• Process Failure Mode and Effect Analysis (PFMEA),
• Inspection Standards,
• Defect and Non-Conformance analyses to Root Cause,
• Containment and control of non-conformances,
• Training Records
o Quality Process Control
• Develop and update Quality Plans.
• Implementing Work Packages/Inspection plans, Inward Inspection, Witness and Hold Points, In-Process and Final Product Inspection, Sampling Plans, inspection, and acceptance criteria.
• Develop and monitoring on treatment of non-conformities products.
• Coordinate with Material, Engineering and Production to resolve customer complaints and concerns.
o Qualitative and Quantitative Data Analysis
• Recommend changes to processes based on the findings and perform follow up to verify effectiveness.
• Participate in the development of Failure Mode and Effects Analysis (FMEA).
• Investigate product quality problems, determine root cause, gather, and analyse data and implement corrective action to reduce or eliminate cause.
• Routinely review regular inspection data and prepare statistical and operational performance reports.
• Monitor and/or perform quality activities to support First Article Inspection, First of Checks, Daily machine checks and ensure Maintenance is performed on time.
• Use quality tools and practices to establish approval criteria to ensure the identification of quality failure concerns for both internal and external manufactured parts and assemblies.
• Provide data input for quality cost.