Rafael (Soares) A.
Certified Quality Engineer
Experience
Dec 2024 - Present
10 monthsHead of Quality
Helsing AI
- Lead new manufacturing companies (Resilience Factories) worldwide based on NATO requirements for aerospace (Part21G/Part21J)
- Implement quality methodologies and tools (RCCA, NCRs, MRB, special process qualification)
- Implement and obtain EN9100 certification
- Point of contact for defense customers (Ministries of Defense) regarding quality and AQAP
- Develop quality processes for qualification and certification
- Plan and execute lean manufacturing to improve quality and reduce costs
- Build the quality, manufacturing, and supply chain organization
Oct 2022 - Dec 2024
2 years 3 monthsMunich, Germany
Director Supply Chain & Quality Operations
Mynaric LaserComm
- Responsible for meeting ramp-up challenges through business excellence and continuous improvement
- Responsible for developing and managing supplier requirements and development
- Establish supply operations structure including supplier selection, development, and continuous improvement
- Build the quality management system (EN9100) and ensure manufacturing process readiness
- Develop the company from an engineering to a manufacturing organization (design to production)
- Responsible for implementing a new ERP system
- Responsible for supply chain operations, quality engineering, quality inspectors, quality management, customer quality, and new program development
- Lead the company in introducing and cascading KPIs and goals (Hoshin Kanri)
Sep 2021 - Oct 2022
1 year 2 monthsGermany
Customer Quality Manager
Harmonic Drive
- Responsible for developing and managing customer requirements (gears, actuators, and electric motors)
- Develop, audit, and improve quality systems for special environments
- Lead development of future aerospace products
- Responsible for deploying EN9100 Rev D in the quality management system
- Develop quality improvement plans and cost reduction initiatives for aerospace segments
- Responsible for fostering corporate quality culture and methodologies to improve overall performance
Jul 2019 - Sep 2021
2 years 3 monthsSupplier Quality Manager
Embraer Executive, Commercial and Defense
- Responsible for developing and managing suppliers (engines, avionics, hydraulics, and flight control systems)
- Implement data-driven risk management to foresee and prevent issues and shortages
- Develop a web-based RCCA methodology to support quality investigations based on Part21G & J and EN9100, automating assessments of safety impact, criticality, cost, and schedule delays using machine learning
- Develop, audit, and improve Embraer quality requirements based on regulatory continued airworthiness standards
- Lead supplier development and performance management (OTD, cost, quality, and continued airworthiness)
- Implement an excellence plan based on the Zero Defective Plan methodology
- Audit, develop, and certify repair centers (Part 145)
- Develop and support aftermarket product quality using data mining
- Responsible for risk and crisis management within the quality organization
Jul 2017 - Jul 2019
2 years 1 monthQuality Manager
Embraer SA
- Manage quality systems (ISO, FAA, ANAC, and EASA regulations for Part 21 & Part 145)
- Responsible for the quality engineering team in key areas (machining, special treatments, final assembly, and fleet support)
- Implement Industry 4.0 (IoT) in main production areas
- Manage special process qualifications and chemical laboratory
- Manage non-conformities and corrective actions using the A3 methodology
- Develop quality plans and preventive actions
- Performance management and KPIs (reducing cost of poor quality, non-conformities, escalated audits, fast responses)
- Agile management - SCRUM (projects and Kaizen)
Jan 2012 - Jul 2017
5 years 7 monthsSupplier Quality Engineer
Embraer SA
- Quality specialist in system and equipment (engine, electrical, hydraulic and flight control system)
- Product and process audits (AS9100) in suppliers and PPAP evaluation and approval
- Conduct problem solving actions using 8D methodology
- Conduct preventive plans in the suppliers
Jan 2011 - Jan 2012
1 year 1 monthSupplier Quality Engineer
Toyota SA
- Special process audits (QTF - Toyota Motor Corporation methodology) in suppliers and sub-tiers
- Manufacture process audits in the suppliers
- Quality assessment implementation (Toyota Motor Corporation quality management)
- Development of new ERP system and supplier data analytics
- RCCA using the A3 methodology
- Preventive actions in the suppliers to achieve zero defects (Kakotora)
Languages
English
NativePortuguese
NativeGerman
IntermediateEducation
Sep 2021 - Oct 2022
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MBA · Project Management
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Production Engineer · Production Engineer
Certifications & licenses
EN9100 Certification
Quality Engineer
ASQ
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