Elżbieta Nowicka
Quality Engineer · Quality Assurance
Warsaw, Poland
Quality Engineer with deep expertise in AS9100 compliance, supplier quality management, and first article inspection (FAI) per EN 9102. Manages non-conformance reporting (NCR) process and leads root cause analysis using 8D methodology. Experienced in NADCAP audit preparation for special processes.
Expertise
- AS9100 Rev D compliance and internal auditing
- non-conformance reporting (NCR) and 8D root cause analysis
- first article inspection (FAI) per EN 9102
- supplier quality audits and qualification
- NADCAP special process auditing (welding, NDT, coating)
- measurement system analysis (MSA)
- statistical process control (SPC)
Technologies
Work History
2024-10
Prepared company for NADCAP audit of welding special processes. Updated procedure set, conducted mock audit, trained 6 welders on documentation requirements, achieved NADCAP accreditation on first attempt.
Challenge: NADCAP welding checklist has 180+ requirements. Identified 12 gaps in our existing procedures 4 months before the audit — enough time to close all of them without rushing.
Learned: Starting NADCAP preparation 6 months before the audit is the minimum. Starting 3 months before guarantees stress. NADCAP auditors find things that internal audits miss.
2024-03
Conducted first article inspection (FAI) per EN 9102 for 8 new parts entering production. Reviewed design documentation, material certifications, process records, and dimensional measurement report.
Challenge: Two parts failed FAI on surface roughness — supplier used wrong cutting parameters. Required supplier to resubmit with corrected machining process and updated control plan.
Learned: FAI is the quality gate before production starts. Passing all 8 parts at first submission is rare — the value of FAI is catching problems before 50 units are made, not just at unit 1.
2023-07
Managed 14 non-conformance reports (NCRs) on machined parts from a new supplier. Used 8D methodology for root cause analysis — identified that the supplier's CNC program had an outdated tool offset table.
Challenge: The supplier initially rejected the NCR, claiming dimensions were within their internal tolerance. Provided measurement data from our CMM vs their CMM — found 0.02mm systematic offset indicating calibration difference.
Learned: NCR disputes with suppliers are often measurement system disagreements, not process failures. Always verify CMM calibration chain and measurement method before escalating.
2023-01
Led AS9100 Rev D internal audit across manufacturing, engineering, and procurement departments. Issued 7 minor findings and 2 major findings. Tracked corrective actions to closure before external audit.
Challenge: One major finding (missing risk-based approach in procurement) required process redesign, not just a procedural fix. Worked with procurement lead to define supplier risk tiering criteria and update the procedure.
Learned: Major audit findings almost always reveal a process gap, not just a documentation gap. Fixing only the documentation without addressing the underlying process will result in a repeat finding.