Senior Quality Assurance Engineer

Job Purpose Support and maintain quality assurance activities for Metal Injection Moulding (MIM)products from incoming material through in-process and final inspection. The role combines manufacturing quality support, customer quality engineering, first-article measurement and CMM-based dimensional evaluation to ensure product conformity, timely issue resolution, and continual improvement. Key Responsibilities 1. First Article Inspection and CMM Measurement • Coordinate First Article Inspection (FAI) for new, revised, or transferred parts and process changes. • Plan and coordinate dimensional measurement using CMM and other suitable metrology equipment. • Review FAI/FA measurement reports and confirm conformance to drawings, GD&T, specifications, and customer requirements. • Support development of inspection methods and measurement programmes for complex features. 2. Customer Quality Engineering • Support customer complaints, quality alerts, returns, and corrective-action requests. • Coordinate containment, root-cause analysis, 8D/CAPA reports, and effective verification. • Communicate quality status and closure evidence with customers and internal teams. • Support customer audits, PPAP/FAI submissions, and customer-specific requirements. 3. Manufacturing Quality Control • Support incoming, in-process, final, and outgoing inspections for MIM products. • Review SPC data, inspection records, rejects, and process-control effectiveness. • Coordinate disposition and follow-up of non-conforming products. • Work with Production and Engineering to resolve day-to-day quality issues. 4. Supplier Part Quality Issue Management (MIM Process) • Support supplier corrective actions, supplier audits, and performance monitoring. • Review incoming inspection results and follow up on supplier quality issues. • Support supplier development and improvement activities. • Communicate and coordinate with suppliers on quality issues and non-conformances. • Issue and track corrective action requests (CAR/SCAR). • Analyze root causes and verify effectiveness of corrective actions. • Support internal stakeholders on supplier-related quality concerns. 5. MIM Process Engineering • Support process development and optimisation for feedstock, injection moulding, debinding, sintering, and secondary operations. • Monitor process capability, yield, scrap, and defect trends; support corrective and preventive actions. • Support process trials, NPI, process transfer, and process validation activities. • Work with Production and Engineering to establish and improve process parameters, work instructions, PFMEA, and Control Plans. 6. Quality System and Improvement • Maintain quality records, reports, controlled documents, and ETQ entries. • Support internal and external audits, document revision, and change-control activities. • Participatein defect reduction, cost improvement, and risk-reduction projects. 7. IMDS and Automotive Material Compliance • Prepare, maintain, and update IMDS submissions for applicable automotive parts and materials. • Ensure material compliance information is available for PPAP, customer submissions, and product-change activities. • Maintain traceable records of IMDS submissions, approvals, and revisions. Qualifications & Requirements • Diploma or Degree in Mechanical, Materials, Metallurgical, Manufacturing Engineering, or a related discipline. • Candidates with exposure to powder metallurgy, Metal Injection Moulding (MIM), or polymer/metal processing will be preferred. • IATF16949 Internal Auditor training or certification is an advantage. • Training in automotive quality tools, including APQP, PPAP, FMEA, MSA, SPC, and IMDS, will be advantageous. • At least 3years of experience in MIM, PIM, precision engineering, moulding, or a similar manufacturing environment is preferred. • Experience in supporting engineering projects, NPI, process improvement, product industrialization, or production troubleshooting. • Understanding of the MIM process flow: powder metallurgy, feedstock preparation, injection moulding, debinding, sintering, secondary operations, and inspection. • Able to read and interpret engineering drawings, specifications, and GD&T. • Familiarity with moulding parameters, process capability, yield improvement, defect analysis, and root-cause analysis. • Knowledge of basic quality tools such as 5 Why, Fishbone, FMEA, control plan, SPC, and 8Dis an advantage. • Able to use MS Excel for data analysis, reports, project tracking, and presentation. • Familiarity with CAD software, CMM, or dimensional measurement equipment is an advantage. • Understanding of APQP, PPAP, IMDS, and IATF 16949 requirements is an advantage for automotive MIM projects. • Strong problem-solving and analytical thinking. • Good communication and coordination skills with Production, Quality, Tooling, suppliers, and customers. • Able to manage project timelines, priorities, and follow-up actions. • Detail-oriented, organised, and quality-conscious. • Able to work independently while contributing effectively in a cross-functional team. • Willingness to learn, adapt, and work hands-on in a manufacturing environment.