Quality Person in Sheet Metal Fabrication

The Quality Person in Sheet Metal Fabrication for the Paint and Powder Coating Plant is responsible for ensuring that all sheet metal parts produced in the fabrication department meet the required quality standards before they proceed to the paint and powder coating processes. This includes overseeing the fabrication process, performing inspections, identifying defects, and ensuring compliance with quality standards. The individual in this role plays a key role in preventing defects, reducing scrap, and ensuring the final product meets customer specifications and industry standards.

Key Responsibilities:

Quality Control in Sheet Metal Fabrication

• Inspect and verify the quality of sheet metal parts and components, ensuring they are free from defects such as scratches, dents, or distortions that could affect the final paint and coating finish.
• Perform dimensional checks and ensure that all parts conform to technical drawings and specifications using measurement tools like calipers, micrometers, and gauges.
• Monitor the fabrication process, ensuring that fabrication techniques (cutting, welding, bending, etc.) are followed to maintain product quality.
• Identify and record any non-conformities during fabrication, ensuring that corrective actions are taken before moving to the painting and coating stages.

Surface Preparation and Pre-Coating Inspection

• Inspect metal surfaces for cleanliness, ensuring they are free of contaminants (e.g., oil, grease, dirt, rust) before they are sent for the paint or powder coating process.
• Ensure proper surface treatment (e.g., sandblasting, acid etching) is carried out as required for optimum paint adhesion.
• Collaborate with the production team to ensure that metal parts are adequately prepared for coating processes.

Process Monitoring & Documentation

• Ensure proper documentation of quality control activities, including inspections, measurements, and non-conformities found during the sheet metal fabrication process.
• Maintain quality records of materials used, inspections performed, and any corrective actions implemented.
• Ensure compliance with internal quality standards and industry certifications (e.g., ISO 9001) during the sheet metal fabrication process.

Defect Identification & Root Cause Analysis

• Identify defects during sheet metal fabrication that could affect coating quality, such as warping, misalignment, or incorrect cuts.
• Conduct root cause analysis for any quality issues discovered and collaborate with the production team to resolve the issues and implement corrective actions.
• Prevent recurrence of defects by identifying and suggesting improvements in the fabrication process.

Collaboration with Paint and Powder Coating Teams

• Work closely with the paint and powder coating teams to ensure that the metal parts meet the requirements for optimal coating performance.
• Ensure that the metal parts do not have any issues (e.g., unlevel surfaces, oil residue) that could affect the final finish during the coating process.
• Ensure that parts are inspected post-coating for defects such as runs, sags, uneven finishes, or poor adhesion.

Supplier Quality Control

• Inspect and verify the quality of incoming raw materials (e.g., sheet metal, fasteners) from suppliers to ensure they meet specifications and quality standards.
• Work with the procurement department to communicate any issues with material quality and collaborate on corrective actions.
• Perform periodic audits of suppliers to ensure continued material quality.

Training and Development

• Train production staff in quality standards for sheet metal fabrication, focusing on techniques that minimize defects during fabrication and ensure the best outcome for paint and coating.
• Promote awareness of quality standards across the fabrication department and ensure that team members understand the importance of quality in the painting and coating process.
• Provide feedback to the team to improve their understanding of quality issues and continuously improve their skill sets.

Health, Safety, and Environmental Compliance

• Adhere to and enforce safety protocols during fabrication processes, including the safe handling of materials and equipment.
• Ensure that all activities are performed in compliance with environmental and safety regulations (e.g., OSHA, EPA) to maintain a safe working environment.
• Ensure the use of appropriate personal protective equipment (PPE) during fabrication and inspection tasks.

Customer Feedback and Complaint Resolution

• Address any quality-related issues or complaints from customers regarding the metal fabrication or coating quality.
• Collaborate with customer service teams to resolve complaints, and provide solutions for improving quality based on customer feedback.
• Ensure any customer-specific requirements are met during fabrication and coating processes.

Continuous Improvement Initiatives

• Actively participate in continuous improvement programs (e.g., Six Sigma, Kaizen, Lean Manufacturing) to identify opportunities for reducing waste, improving quality, and enhancing production processes.
• Implement best practices for sheet metal fabrication and paint/powder coating, and suggest innovations that could improve the overall manufacturing process.

Qualifications:

Education:

• High school diploma or equivalent required.
• Associate’s or Bachelor’s degree in Mechanical Engineering, Materials Science, or a related field is preferred.

Experience:

• Minimum of 2-3 years of experience in quality control or quality assurance in a sheet metal fabrication or manufacturing environment.
• Experience with quality control procedures specific to metalworking, welding, and surface preparation for painting and powder coating is highly desirable.

Skills and Competencies:

• Strong understanding of sheet metal fabrication processes such as cutting, welding, and bending.
• Knowledge of surface preparation techniques and how they impact the quality of paint and powder coating.
• Proficiency in the use of quality control tools, such as calipers, micrometers, and gauges.
• Strong attention to detail and ability to identify defects in materials and finished products.
• Good analytical and problem-solving skills to identify root causes and implement corrective actions.
• Effective communication skills, with the ability to collaborate across departments and report findings to management.
• Basic understanding of quality management systems (ISO 9001) and industry standards for metal fabrication and coating.

Certifications (optional but preferred):

• Knowledge of welding and fabrication techniques.
• ISO 9001: Quality Management System training or certification.
• Lean or Six Sigma certification.
• Forklift operation certification (if required for material handling).

Work Environment:

• Work is performed in a manufacturing facility, which may involve exposure to noise, chemicals, welding fumes, and high temperatures.
• Personal protective equipment (PPE) such as safety glasses, gloves, ear protection, and safety shoes are required.
• The position may require shift work or overtime depending on production schedules.

Physical Requirements:

• Ability to stand for long periods of time and move around the manufacturing floor.
• Ability to lift and carry up to 25 lbs of materials.
• Capability to work in varying temperature conditions, including hot or cold environments during fabrication processes.

Key Performance Indicators (KPIs):

• Defect rate in sheet metal parts and components.
• Compliance with fabrication standards and specifications.
• Reduction in scrap and rework rates.
• Customer complaints related to fabrication and coating quality.
• Efficiency in identifying and resolving fabrication-related quality issues.