OVERALL JOB PURPOSE
To support the implementation, maintenance and continuous improvement of rigorous quality processes with a specific focus on Advanced Product Quality Planning (APQP) and New Product Introduction (NPI)
To ensure the highest quality product, authorised as compliant to the relevant nuclear and safety regulations, is delivered to our customers without defect, on time.
To act as a key interface within a Project Team, driving nuclear safety culture and ‘right first time’ delivery throughout a programme.
KEY TASKS
- NPI & APQP Leadership: Lead the internal cross-functional team through the full APQP lifecycle ensuring all deliverables, from Feasibility Reviews to Volume Production are met on schedule.
- PPAP Management: Compile, review, and submit comprehensive Production Part Approval Process (PPAP) files (typically Level 3 submissions), ensuring all evidence (including Part Submission Warrants, Control Plans, and Process Flow Diagrams) meets customer specifications before volume manufacturing commences.
- Non-Conformance & Root Cause Resolution: Manage investigations and support the timely resolution of Customer, Supplier, and internal non-conformances. Champion Root Cause Analysis to ensure containment (within 24 hours) and implement robust corrective/preventative actions to prevent recurrence.
- Auditing & Oversight: Lead the internal, external, and supplier auditing programme. Conduct specific oversight of Special Processes (e.g., Welding, NDE) and conduct Launch Readiness Reviews (LRR) to verify supply chain capability.
- Compliance & Traceability: Ensure products have full traceability and conformance documentation throughout the manufacturing process. Oversee the collation of accurate Lifetime Records (LTR) and Material Certification (BS EN 10204 3.1), ensuring protection against Counterfeit, Fraudulent, and Suspect Items (CFSI).
- Process Control & Validation: Develop and maintain dynamic Control Plans (Prototype, Pre-production, and Production). Verify manufacturing readiness through Run@Rate trials and Process Capability studies (Cp/Cpk) to ensure OEE and capacity targets are met.
- Customer & Supplier Collaboration: Liaise with customers and suppliers to troubleshoot problems. Support the wider project team including the customer to ensure non-compliant or defective parts are excluded from the build process and compliant disposition is agreed upon.
QUALIFICATIONS
- Qualification in Engineering (apprenticeship, HNC or degree) is desirable.
- Trained in QMS auditing techniques.
SKILLS
Essential Technical Skills:
- Extensive knowledge of APQP (Advanced Product Quality Planning) and PPAP (Production Part Approval Process)
- Proficiency in the core Quality tools: FMEA (Failure Mode and Effects Analysis), MSA (Measurement System Analysis) and SPC (Statistical Process Control).
- Trained in Statistical Analysis techniques and validation methods.
- Ability to read Engineering drawings and geometric tolerancing.
- Familiar with root cause analysis techniques (8D, 5 Whys, Fishbone diagrams)
Software:
- Proficient user of Microsoft Office (Word, Excel, Outlook)
- Experience with statistical software (eg Minitab) for MSA and Capability studies is advantageous.
- Welding technologies – MIG and TIG (particularly Stainless Steel and Aluminium Alloys) and robotic welding.
EXPERIENCE
Essential:
- Substantial Quality experience within a similar, regulated manufacturing environment (Nuclear or High-Integrity sectors preferred)
- Experience managing Lifetime Records (LTR) and ensuring full lot traceability and material certification verification.
- Extensive auditing experience including internal, external and supplier audits.
- Proven experience in New Product Introduction (NPI) and managing the transition from prototype to volume production.
- Experience managing Special Processes (Welding, NDE, Coatings) and understanding ‘Engineering Control’ vs ‘Manufacturing Control’ classifications.
Desirable:
- Weld types, weld processes and NDT (non-destructive testing) techniques
- Experience with ISO 14001, ISO 45001 and pressure equipment standards (eg AMSE BPVC, PD5500, EN13445
- Welding technologies – MIG/TIG (Stainless Steel and Aluminium Alloys) and robotic welding
KNOWLEDGE
Essential:
- Understanding of Nuclear Safety Culture and how workmanship quality impacts nuclear safety.
- Knowledge of Counterfeit, Fraudulent and Suspect Items (CFSI) mitigation.
- Kaizen, Lean, Root Cause Analysis and Statistical Reporting Methods.
Desirable:
- Understanding of Product Verification Levels (PVL) and risk-based inspection regimes.
- Foreign Material Exclusion (FME) practices.
- Weld types, weld processes and NDT (non-destructive testing) techniques.
PERSONAL CHARACTERISTICS
- Intelligent Customer Mindset: Ability to drive supplier performance and act as a "guiding mind" for quality deliverables.
- Proactive Leader: Confident team player, able to work on own initiative and lead a team to achieve desired outcomes.
- Detail-Focused: Methodical approach to data analysis, record-keeping, and "Right First Time" documentation.
- Resilient: Ability to work well under pressure in a demanding, high-integrity environment.
- Communicator: Excellent communication skills with a professional and responsible approach.
RISK FACTORS
- Risk of failure to maintain Company understanding and compliance of current regulations, which may result in a loss of accreditation and loss of business.
- Risk of allowing non-conformance in the manufacture of regulated components, resulting in avoidable reworks, delivery of non-conforming components or health and safety issues.
- Risk of unmonitored activities leading to key area failures, resulting in the potential for underperforming or non-conformance of product.
MANDATORY RESPONSIBILITIES
All employees of LTi Metaltech, LTi Vessco and Metaltest are expected to promote and reflect the values of the business when representing the Company and in their dealings with colleagues, customers, suppliers and services alike and to operate in accordance with them.
All employees of LTi Metaltech, LTi Vessco or Metaltest, all staff have the following responsibilities:
- To reflect the values of LTi and operate in accordance with them, namely: Responsible, Collaborative and Progressive
- Take responsibility for aspects of Occupational Health & Safety (OH&S) over which they have control.
- Adhere to the Company’s OH&S requirements (defined in OH&S policy, risk assessments, work instructions and through training, etc.).
- Take reasonable care for their own health and safety as well as the safety of other persons who may be affected by their acts or omissions.
- Work in accordance with information and training provided.
- Refrain from intentionally misusing or recklessly interfering with anything that has been provided for health and safety reasons.
- Report any hazardous defects in plant and equipment, or shortcomings in the existing safety arrangements, to a responsible person without delay.
- Not undertake any task for which authorisation and / or training has not been given.
- To promote and maintain a culture of continued Risk Assessments.
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