Job Description

Member of the Quality Assurance Team. Provide support and education to operators, process engineering, and supervisors in the Bar Mill, Cast Shop, Rolling Mill, and Extrusion Mill (Mebane, NC). Monitor, control and make recommendations for improvements to various phases of manufacturing processes and equipment. Lead projects focused on continuous improvement of production processes. Ensures products meet customer and industry specifications by developing and maintaining quality standards, controls plans, and corrective actions. Leads root cause analysis and problem-solving for product and process nonconformances.

Duties and Responsibilities:

• Investigate production process needs.
• Coordinate and implement projects and action plans to drive improvements to key quality metrics such as yield, remakes, etc.
• Assure processes used to manufacture products meet or exceed customer and industry expectations.
• - Determine alternative processing options to best utilize available capacity on mill machinery.
• Review and make recommendations for changes to Revere ASTM/CDA representative on various documentation and standards as requested.
• Analyze and respond to customer complaints and corrective action requests:
• - Investigates and executes Root Cause and Corrective Actions utilizing quality tools such as 8D, 5Y, Ishikawa diagram, etc.
• - Refer off-quality products to affected Customers through Customer Support
• - Visit Customers, Outside Processors and MRO Vendors plants as necessary.
• Apply Technical Applications of Quality Engineering:
• - Perform Capability and Control Statistical Studies internally and externally.
• - Support various APQP demands.
• - Use various diagnostic equipment and tools to monitor various Process Parameters.
• - Perform simple laboratory testing such as pH, Hardness, Conductivity.
• - Conduct process walks to observe material, processes, and operators.
• - Create disposition of Non-compliant Product.
• - Troubleshoot process/equipment issues leading to nonconforming products.
• Develop and maintain quality tools such as Capability Studies, Gaging R&R, Process Flow Diagrams, etc.
• Lead /participate in Mill Tours to visiting Customers, Vendors, and Community Members as requested.
• Attend periodic meetings with Operations, Quality, and Sales & Marketing.
• Creates and Modifies Job Instructions, Quality Assurance Plans, JIB’s, OJT’s etc. within Revere Document Control System.
• Initiates New Material Request Documentation for new and experimental materials used in processing and/or testing. Participates in Audits by Independent 3rd Parties and Customers.
• Perform Internal Audits, write audit findings, and lead discussions at Audit Closing Meetings.
• Performs metallographic investigations on various samples to help determine root cause of defects when necessary.
• Reports Key Process and Product Metrics to various levels of the organization.
• Uses various diagnostic equipment and tools to monitor different Process Parameters. These include; dimensional gauging tools, thermometric devices, process data recording devices, hand-held tools, hand-held Profilometers, etc.
• Support the Purchasing department in managing supplier quality.

Requirements

Qualifications:

Minimum:

• 1 – 3 years' experience as a Process Engineer in the production of Primary Metals (Steel, Aluminum, Copper) with knowledge and understanding of the relationship between process inputs and outputs.

Preferred:

• 3 – 5 years of experience in the manufacture and quality management of primary metals (Copper, Steel, Aluminum), Mechanical and Physical material testing of metals.
• Experience in Problem Solving Methodology, Containment and Corrective Action Processes, APQP techniques.
• Thorough knowledge of Statistical Process Control techniques.

Special Demands:

• Lifting/Handling various product samples that may have sharp edges or burrs.
• Exposure to Corrosive and volatile process Chemicals.
• Extremities of Heat/Cold mill environments.
• Possible dusty/smoky environments.
• Loud noise environments.
• Walking distances up to ¼ mile between various locations within the mill.
• Climbing/Descending Stairs and Ladders within the mill and offices.
• Exposure to mobile equipment and overhead cranes.
• Standing for long periods.
• Possible slippery floors and walkways.
• Outdoor work is possible.
• Reduced lighting environments are possible.
• Proximity to moving machinery.
• Occasional overnight travel.

Minimum:

• Bachelor’s degree in a Physical Science (Physics, Chemistry) or Mechanical Engineering, Mechanical Technology, or Chemical Engineering.
• Knowledge of Statistical Techniques is a plus.
• Proficiency in Microsoft Office products.

Preferred:

· Bachelor’s degree in Material Science, Extractive Metallurgy, or Refractory Engineering. Six Sigma Certification, and experience in APQP methodology.

· Graduate studies or Master’s degree.