Quality Assurance Auditor (QA Auditor)
Falcon Aviation Services
Total years of experience :16 years, 5 Months
Plan and conduct internal audit (Cost based and risk based) and external audit, inspections and investigations on 145, CAR M and EASA Part 145 by leveraging on a wide range of audit techniques to identify risks and potential issues in order to support their timely and accurate resolution
Provide suggestions to Departmental Managers as part of Audit Feedback to promote best practices to achieve the overall audit objective of optimal risk protection
Support the development of Safety Management System (SMS) to provide necessary expertise on own area of responsibility
Conduct investigations on maintenance related incidents, accidents, and process errors and evaluate the causal factors to ensure accurate tracking in case of audit
Map existing processes to identify the improvement opportunities and develop procedures, process maps, or work instructions accordingly.
Conduct reviews and assess qualifications of all aircraft engineers and authorization holders to ensure compliance with GCAA/ EASA/ FAA/GACAR regulation, internal procedures and standards
Conduct reviews, assess capabilities, and report on new aircraft, aircraft components, and facilities to ensure compliance with regulation, internal procedures and standards
Plan, design and lead the business process review exercise to identify high-risk processes with inputs from the customers and group departments. Create action plan using a risk based approach and own delivery of the plan.
Establish Quality Management System policies and procedures by regular and surveillance audits.
To draft and make improvements in Quality Control Plan, Inspection Plan, acceptance test plan (ATP), and FMEA,
Preparation of all documents like Industrial Quality Dossier, Manufacturing Dossier, Project Development Plan adhering to AIRBUS GRAMS requirements.
Support Internal Audit team and external Agencies like GCAA and BCA, to conduct product, process and compliance audits.
Organize weekly Corrective Action Board meetings (CAB) with M&P Engineer and Production Supervisors to show First Time Quality and drive investigations if required.
Coordinate with Production, Engineering, Procurement and Programs for the bottlenecks in on time delivery schedule and ensure they are addressed effectively to meet the schedule.
Prepare corrective action plan and monitor its implementation for the audit findings.
Coordinate with Customers (AIRBUS, SAAB and SABCA) for the final delivery of the A350-900 and A350-1000 Flap Support Fairings and prepare the Quality Shipment Documents.
Acknowledge the Customer Complain and coordinate with Production to carry out Root Cause and Corrective Action Analysis.
Guide and Mentor the inspectors to ensure the Product Quality.
Keep track of the non-conformities and ensure its timely disposition.
Keep track of the delivery status and post-delivery feedbacks
Establish an audit program (Time and Risk Based) that provides assurance to governance processes, implementation and effectiveness of systemic processes and accuracy of data integrity and reporting.
Be part of Engineering Modification Committee Meetings for the respective area so that timely action is initiated as required.
Represent Quality Team in daily pre-flight briefings make note of the customer complain and work closely with design team for the improvement process,
Work in close coordination with Government Agency (DGAQA) and ensure the Customer satisfaction by maintaining high standard of Quality in the Product.
Inspection and pre-installation testing of critical components used in aircraft such as various LRUs like Actuators, Valve Assemblies and NRVs
Preparation of various quality reports, and metrics to monitor the areas of improvement.
Inspection of manufactured aerostructures such as wings and flight control surfaces (ailerons, flaps, elevators and rudder) of Intermediate Jet Trainer (IJT)
Conduct internal audit and supplier audit as per AS9100 C and ensure the compliance as per the standard.
Manage all operational performance aspects of suppliers and work with them to maximize their ability to meet quality, delivery and cost objectives
Plan, organizes, and conducts supplier audits, surveys, and inspections at supplier end to ensure timely delivery of products
Worked on the aerospace structure and flight control systems of various military aircrafts such as HAL Light Combat Aircraft (LCA), HAL Intermediate Jet Trainers (IJT), BAE Hawk, Mirage-2000, and Sukhoi-30 MKI
Lead of Quality Inspectors and Quality Engineers and provide technical guidance to them on interpretation of Drawings, Process Specifications, and Work Instructions.
Validate the manufacturing work instructions to ensure product compliance with specifications and ensure integration of inspection steps in the right sequence in the manufacturing process.
Support the development of Safety Management System (SMS) to provide necessary expertise on own area of responsibility.
Work closely with Boeing SQA and DCMA for the product buy of for F15SR wings, Forward Fuselage and on wing support structures like Pylon and Adaptors.
Maintain Qualification Matrix for the Inspectors, technicians and authorization holders to ensure compliance with regulation, internal procedures and standards.
Conduct reviews, assess capabilities, and report on new aircraft, aircraft components, and facilities to ensure compliance with regulation, internal procedures and standards.
Drive continuous improvement in first pass quality and take proactive actions by issuing Corrective Action Request (CAR) to ensure reduction in non-conformities and cost of quality.
Monitor the documentation of CAR and other improvement opportunities and alleviate as required to the top Management using Q-Pulse for the effective implementation.
Organize, synthesize, and analyze data; summarize findings; develop conclusions and recommendations by using appropriate metrics.
Develop and maintain the QA Plan and existing Quality Manual. Update existing QMS for any shortcomings or process improvements.
Develop complex visibility tools and appropriate metrics to monitor quality performance of shop floor and identify the areas of improvement.
Coordinate the investigation of customer complain and ensure its timely resolution.
Develop models, data bases and spreadsheets to analyze data (e.g., quality performance, Internal / GACA/TUV) and provide expert guidance to management and Quality team to formulate plan and guide implementation of processes to enhance quality performance.
Prepare Why-Why analysis for any deviation in the completed product and get it incorporated so that particular non-conformance could be avoided in next product.
Monitor and maintain appropriate metrics to measure the capability of my team, and identify the improvements and training opportunities