A leading automotive supplier is seeking an experienced quality expert to inspect weld seams on safety-critical body components. The project involves 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 welding and production planning. Calibration and maintenance of testing equipment.
- Relevant technologies/tools: Ultrasonic testing equipment, 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: Assessment of complex seam geometries under time pressure. Clear interpretation of test results and distinction between acceptable irregularities and critical defects. Enforcement of quality standards with production.
- Deliverables: Completed test protocols, detailed failure analyses and reports, updated work and test instructions, contributions to FMEAs (Failure Mode and Effects Analysis).
- Best practices: Regular team coordination (shopfloor management), continuous improvement of testing processes (CIP), raising awareness and training of production staff.