Additionally, the QA Engineer will be tasked with facilitation and deployment of the Vallourec Management System, with primary focus on Lean Management. They will lead and train the team in our Lean Management System including such methods as 5S, 2 Second Lean, TPM, standardization, workflow analysis, value stream mapping, and Six Sigma.
KEY RESPONSIBILITIES:
Maintain and improve standard procedures; support training of the operators and inspectors on inspection and gaging techniques and the use of procedures.
Assist in the control of material certification documents. Monitor quality records.
Monitor work order packets for accuracy and acceptability.
Support and maintain documented processes for ordering, receipt and control of gages and related documents.
Supervise other QA personnel as required.
Generate or revise QA documents such as procedures, work instructions and specifications as needed; and train affected personnel on such documents.
Interface with subcontractors on clarification of quality requirements.
Use knowledge of product and inspection/testing requirements to collect data and perform evaluation when customer issues arise. Utilize 8D problem solving to address customer claims.
Implement and maintain program of root cause analysis and corrective action of non-conformance to reduce variation of key process indicators, mitigate rework, reduce cost and improve quality.
Collect appropriate data and use advanced problem solving techniques such as process capability, SPC, FMEA and Design of Experiments to isolate and reduce sources of variation and to resolve production and quality issues.
Review customer specifications/requirements to evaluate capability and develop quality plans as needed.
Perform internal and supplier/subcontractors process and management system audits as scheduled or needed.
Support project activities and product industrialization by working with operations, operations technology, research and development, product engineering, industrial performance, planning/scheduling, and external suppliers/organizations.
Support and/or facilitate all continuous improvement efforts associated with Safety, Quality, Operational Excellence and Cost.
Support the development and implementation of all levels of the hourly Skill Based Development program as it relates to Lean and Six Sigma methods.
Support team members to deploy the appropriate Safety / Quality / Delivery / Cost / People metrics and management routines at all levels of the organization.
Perform Six Sigma projects and act as expert/coach for other members seeking Six Sigma certification.
Assist leadership in the planning, development, coordination, support, and execution of strategic planning process, and take ownership of high impact (immediate and long term) improvement projects.
Follow all company policies, practices and regulations to include Quality and Safety.
Any other duties as assigned.
REQUIREMENTS
SKILLS AND KNOWLEDGE:
Strong quality engineering background in manufacturing environment. Experience in machining operations is desired.
Proficiency in wide range of problem solving tools and methods, including Six Sigma Methodology and advanced statistics.
Extensive, in-depth knowledge of quality requirements and systems.
Experience with ISO9001 and API quality/product standards is required
OCTG and connections knowledge is highly desired
Proficiency in Microsoft Office Suite including Excel, and PowerPoint as well as statistical analysis software, such as Minitab
Motivation and will to dig into situations and work with all functions of the business. The ability to work in diverse groups to achieve a common goal is critical to the success of this position.
Ability to effectively communicate with all levels of the organization.
Capability of working independently in a self-directed environment.
Excellent written and verbal communication skills.
EDUCATION, TRAINING, AND CERTIFICATIONS:
BS in quality engineering or in another engineering discipline with quality experience such as Mechanical or Industrial Engineer is required.
Lead auditor training is preferred (ISO 9001, API Q1)
Six Sigma black belt or green belt certification or training preferred
ASQ - Certified Quality Engineer (CQE) preferred
CRITICAL COMPETENCIES & CAPABILITIES:
The position will require demonstrated leadership skills and the ability to concisely communicate objectives and results to reach targeted goals. Strong understanding of quality assurance/process control principles as well as manufacturing quality control methods (inspection and gauging).
