Job Description

About the Role

To provide leadership, management, and coordination for Haynes' Quality Assurance System.

Role Purpose

• To provide leadership, management, direction and coordination for all aspects of Haynes’ Quality Assurance to obtain and/or maintain key Quality accreditations. These aspects include Quality Assurance, Quality Engineering, NDE and Inspection, and Calibrations Systems in Kokomo, as well as, in the Domestic Service Centers. Also, provides expertise and assistance to the Quality groups at Arcadia, Haynes Wire and/or VDM USA, as needed.

• To direct all QA and QE functions of our Quality System leading to the creation of appropriate and acceptable Materials Certification for final products based on compliant intermediate and final material sampling, inspections and testing results and effective internal and external auditing, consistent with ISO 9001/AS 9100 and other customer-specific requirements.

• Develop and execute approved plans to meet anticipated support needs each fiscal year; to provide operations and strategic input to the Director of Quality Systems and Manufacturing Engineering in support of our Quality System; to develop suitable QA, QE, Calibration and Inspection procedures and capabilities.

• To work in conjunction with the Manufacturing Engineering Manager and our Manufacturing/Production Management Team in developing an effective Process/Quality Control and Improvement programs to reduce off-quality costs.

Role Qualifications ( Required & Preferred)

Education: B.S or M.S. (R) in technical discipline, preferably in Metallurgy, Materials Science, Chemical or Mechanical Engineering; Other degrees would be considered depending on experience.

Experience: 5+ years w/ B.S. in Engineering or 3+ years and a M.S. (R); experience in Manufacturing and/or Quality Assurance, preferably related to aerospace metallic materials or another quality system-critical environment.

Areas of Knowledge: QA/QE Systems and best practices, including ISO 9000 & AS 9100 requirements, auditing, standard materials specifications (AMS, ASTM, ASME, etc.) and Statistical Process Control (SPC) (All R); Knowledge of thermo-mechanical and/or melting processing and/or physical metallurgy of Ni- and Co base alloys (P); Manufacturing processes/equipment involved with the production of major Haynes wrought product forms (P).

Skills: Leadership and management, Organization and Project Management, Planning, Technical Communication (written and oral), Observational and Analytical skills (all R); Computer skills (MS Office suite, Minitab, AX, Shopfloor, etc. (P).

Global Accountabilities for the Role

Safety/Environmental – Adhere to/support our corporate safety and environmental policies and ensure direct reports do likewise; Confirm effective measures are taken to ensure work venues and SOP’s are safe, environmentally compliant and consistent with policies.

Quality – Ensure that all QA, QE, NDE and Inspection, and Calibration/Measurement Standard laboratory plans and activities comply with the Quality System, and consistent with policies.

Delivery – Set appropriate expectations, goals and requirements for all assigned personnel regarding safety, quality, delivery and cost, and effectively communicate and monitor progress toward these goals

Cost/Stewardship – Plan, lead and/or participate in assigned QS and Manufacturing projects to ensure yearly commitments are met. Effectively monitor, document and regularly report status, activity and progress in areas of responsibility in a timely manner. Communicate relevant information and directives from senior management to direct reports.

Specific Accountabilities for the Role

• Fulfill responsibilities of the Quality Assurance Management Representative and provide leadership, management, direction and coordination for all aspects of Haynes’ Quality Assurance to maintain all existing Quality accreditations as directed by senior management, and obtain new accreditations as directed.
• Develop and manage backup plans for all critical operations and create plans targeting personnel development to ensure succession for technical knowledge/capabilities for key roles in the Quality area (especially for succession planning).
• Ensure that all sections of the Quality Manual have current revisions reflecting current Quality Assurance policy and practice; maintain responsibility for our controlled documentation system. Also, ensure that all data and information needs of the Quality Assurance Management team are provided, and publish reports on the goals/requirements throughout the company’s operations on a monthly, quarterly and yearly basis. Work with Quality Managers from Arcadia and Haynes Wire to standardize Quality Metrics/Performance reporting on a corporate basis.
• Plan and monitor the fiscal year budgets in assigned departments to effectively support and achieve the fiscal year project plans for our corporate commitments per the VP of Operations.
• Develop training plans and ensure that adequate and appropriate Quality Assurance training is provided and documented for all Haynes employees based on their functions inside and outside the QA group, especially for Quality and Manufacturing Engineers, NDT Engineers, Technicians and Inspectors. This training will include appropriate information about Manufacturing Processes, Metallurgy, QS System, Legal and ethical compliance, and other required company training.
• Ensure that there are effective and continuous efforts to improve our Calibrations, NDT, QA and QE process capabilities and procedures to meet specific department yearly commitments in support of the Manufacturing and Commercial plans.
• Manage and maintain the internal auditing, Non-conformance/Corrective Action program, and RMN systems in support of Sales and customers. Also, provide third party auditing by Haynes Kokomo personnel as resources allow for Ar4cadia and Haynes Wire in support of their Quality Assurance. Investigate customer complaints, provide for root cause analysis and corrective actions. Support Sales and Marketing with technical and quality system requirements as needed.
• Provide leadership and technical direction on the development and maintenance of the Quality – Test – Certification (QTC) system, as well as for the quality requirements of the AX system.
• Provide technical reviews of standard and customer-provided Specification requirements and the corresponding test release criteria based on these QE reviews; participate and direct personnel in the 460 department on updating the QTC system as needed for new requirements (AX) or updated specification requirements.
• Ensure that our Inspection Department personnel receive the proper safety, quality system and required job-specific company training and utilize approved procedures in accordance established SOP and QCI requirements.
• Highlight scrap and rework activity/issues by maintaining the daily and monthly scrap and rework summaries and reports. Also, report major issues and activities in your other areas of responsibility for input into the Monthly Quality System Update Report. Distribute reports in a timely manner (by due date).