Metrology Engineer Apprentice

Core Responsibilities Dimensional Inspection:

• Using advanced measurement equipment to check part thickness, warp, angles, and overall geometry
• First Article Inspection (FAI): Verifying the very first parts Off a new mould to approve the tool for mass production
• Mould Cavity Tuning: Identifying precisely where a mould tool needs to be modified or shaved down if the plastic parts are coming out out-of-spec
• Gauge R&R Studies: Testing and validating the measurement tools themselves to ensure consistency and repeatability across different operators
• Common Tools of the Trade CMM (Coordinate Measuring Machines): Tactile probes that touch specific points on a part to map its dimensions in 3D space
• 3D Scanners: High-tech blue light or laser scanners that create a full digital "point cloud" of a physical part to compare it directly against the original CAD model. Manual Tools - Caliper, Pin Gauges, Micrometer, Feeler gauges, pin gauges etc.
• Material and Quality Testing Devices: Include moisture balances, hardness testers (Shore / Rockwell), and melt flow indexers to inspect incoming polymer resins
• The Quality Core Tools PFMEA (Process FMEA): Focuses on manufacturing and assembly process risks caused by human error or machine failure Advanced Product Quality Planning (APQP) A structured framework used to design and develop products that meet customer requirements before production starts
• Statistical Process Control (SPC) A method that uses statistics and control charts to monitor and manage manufacturing stability over time. Measurement Systems Analysis (MSA) A testing process that ensures gauges and tools measure accurately and reliably. Production Part Approval Process (PPAP) A qualification process that confirms production parts meet exact customer specifications. Control Plan - A living document that outlines the specific manufacturing steps and real-time controls needed to execute risk strategies identified in an FMEA
• Risk and Root-Cause Analysis Tools If you want alternatives focused on problem-solving, risk evaluation, and finding the origin Of defects: Fishbone Diagram (Ishikawa / Cause-and-Effect) A visual chart shaped like a fish skeleton that categorizes potential causes of a problem under headings like Manpower, Machine, Material, and Method. 5 Whys A simple questioning technique where you ask "Why?" five successive times to drill down from a surface symptom to a deep root cause
• Fault Tree Analysis (FTA) A top-down, deductive logic diagram that traces backward from an undesired system failure to find all possible root causes
• Pareto Chart A combined bar and line graph that highlights the vital few defects or issues causing the majority of overall quality failures