Rafael A. - Certified Quality Engineer

Munich, Germany

Experience

Dec 2024 - Present

1 year 1 month

Lead new manufacturing companies (Resilience Factories) worldwide based on NATO requirements for Aerospace/Part 21G and Part 21J
Implement quality methods and tools (RCCA, NCRs, MRB, special process qualifications)
Achieve EN9100 certification
Serve as point of contact to defense customers (Ministries of Defense) on quality and AQAP
Develop quality processes for qualification and certification
Plan and run lean manufacturing to improve quality and cut costs
Build quality, manufacturing, and supply chain teams

Oct 2022 - Dec 2024

2 years 3 months

Munich, Germany

Drive ramp-up through business excellence and continuous improvement
Develop and manage supplier requirements and performance
Set up supply operations: selection, development, and ongoing improvement
Build the quality management system (EN9100) and ensure manufacturing process readiness
Grow the company from engineering to manufacturing (design to production)
Implement a new ERP system
Oversee supply chain operations, quality engineering, inspections, quality management, customer quality, and new program development
Guide the company on KPIs, goal setting, and cascading (Hoshin Kanri)

Sep 2021 - Oct 2022

1 year 2 months

Germany

Develop and manage customer requirements (gears, actuators, and electric motors)
Create, audit, and improve quality systems for special environments
Lead development of future aerospace products
Deploy EN9100 Rev D in the quality management system
Plan quality improvements and cost reduction for aerospace segments
Shape corporate quality culture and methods to boost performance

Jul 2019 - Sep 2021

2 years 3 months

Manage supplier development for engines, avionics, hydraulics, and flight control systems
Use data analytics in risk management to predict and prevent issues and shortages
Create a web-based RCCA tool for quality investigations: automated safety impact, criticality, cost, and delay analysis using machine learning, based on Part 21G & J and EN9100
Develop, audit, and improve Embraer's quality requirements for continued airworthiness
Lead supplier performance: on-time delivery, costs, quality, and continued airworthiness
Implement an excellence plan based on the Zero Defect methodology
Audit, develop, and certify repair centers (Part 145)
Use data mining to improve aftermarket product quality
Oversee risk and crisis management in the quality organization

Jul 2017 - Jul 2019

2 years 1 month

Manage quality systems (ISO, FAA, ANAC, and EASA rules for Part 21 & 145)
Lead quality engineering teams in machining, special treatments, final assembly, and fleet support
Implement Industry 4.0 (IoT) in key production areas
Handle special process qualifications and chemical lab operations
Manage non-conformities and corrective actions using A3 methodology
Develop quality plans and preventive actions
Oversee performance metrics (non-quality cost reduction, non-conformities, audit escalations, quick response)
Use Agile (SCRUM) for projects and continuous improvement (Kaizen)

Jan 2012 - Jul 2017

5 years 7 months

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 month

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)