A leading automotive supplier is looking for an experienced quality expert for inspecting weld seams on safety-critical body components. The project includes ensuring the highest quality standards through non-destructive testing methods.
- Typical tasks: Independent planning, execution, and evaluation of non-destructive tests (NDT), especially visual testing (VT) and ultrasonic testing (UT). Creation and management of test plans and work instructions. Detailed documentation of test results in CAQ systems. Analysis of defect patterns and initiation of corrective actions in close coordination with the welding shop and production planning. Calibration and maintenance of testing equipment.
- Relevant technologies/tools: Ultrasonic testing devices, endoscopes, videoscopes, CAQ software (e.g., Babtec, QSYS), knowledge of standards DIN EN ISO 9712, ISO 5817, and relevant VDA volumes.
- KPIs/success metrics: First Pass Yield (FPY) > 98%, reduction of internal defect rate (PPM), zero-defect tolerance for safety-critical seams (escape rate = 0), timely completion of test orders.
- Special challenges: Assessing complex seam geometries under time pressure. Clear interpretation of test results and distinguishing acceptable irregularities from critical defects. Enforcing quality standards with production.
- Deliverables: Completed test reports, detailed defect analyses and reports, updated work and test instructions, contributions to FMEAs (failure modes and effects analysis).
- Best practices: Regular team alignment (shopfloor management), continuous improvement of testing processes (CIP), raising awareness and training of production staff.