Joanna Kaminska

2025-01

Participated in pilot of AI-powered document search tool for quality standards. Tested queries against AS9100 clause interpretations, NADCAP checklist items, and internal quality procedures.

Challenge: The tool returned relevant documents but citations were sometimes imprecise — pointing to a section rather than the specific clause. For compliance work, clause-level precision is necessary. Provided detailed feedback.

Learned: For quality compliance use cases, AI search must support clause-level citation and include the exact regulatory text in the response. Summarized citations are insufficient for audit evidence purposes.

2024-09

Conducted internal audit of the design control process (AS9100 clause 8.3) — reviewed design review records for 5 development programs. Focus: completeness, timeliness, and traceability of review actions.

Challenge: Design reviews were frequently documented retrospectively — meeting notes written days after the meeting, action items added after they were already completed. Raised 2 CARs for inadequate traceability.

Learned: Retrospective documentation defeats the purpose of design review records as objective evidence. Introduced mandatory real-time meeting notes using a standard template as a process control.

2024-05

Participated in NADCAP audit for heat treatment special process at Warsaw facility. Compiled and presented objective evidence for 64 audit checklist items.

Challenge: One non-conformance raised for incomplete temperature recorder calibration records from 2022 — a period before new records management system was implemented. Root cause: calibration records were stored in a folder on a technician's local drive. Implemented mandatory upload to SAP QM on completion.

Learned: NADCAP auditors look for traceability over long time horizons. Records management practices from years ago can create audit findings today. Retroactive document migration is painful — do it proactively.

2023-12

Managed PPAP process for a new fastener supplier entering the approved supplier list. Coordinated Level 2 PPAP submission including dimensional reports, material certificates, and process flow diagram.

Challenge: Supplier submitted dimensional measurement reports against an incorrect drawing revision — they measured the wrong features. Required full restart of the measurement cycle with 3-week delay.

Learned: Always verify drawing revision alignment explicitly with suppliers before any measurement activity begins. One phone call at the start would have saved three weeks.

2023-09

Led FMEA review for a new sealing system design — elastomeric face seal for HPT rear bearing compartment. Identified 8 failure modes with RPN above threshold requiring design changes.

Challenge: Design team was in Munich, quality team in Warsaw — asynchronous review process dragged on for 8 weeks instead of the planned 3. Items requiring clarification would sit in inboxes for days.

Learned: Cross-timezone FMEA reviews need a dedicated synchronous session for each RPN > threshold item. Asynchronous comment threads do not resolve complex technical disagreements efficiently.

2023-05

Conducted on-site audit of an LPBF additive manufacturing subcontractor. Evaluated compliance with AS9100 and internal additive manufacturing specification for structural bracket production.

Challenge: Supplier had no formal Process FMEA for the LPBF process — only a generic risk register that did not meet AS9100 clause 8.1 requirements. Issued a Major NC requiring CAR within 30 days.

Learned: Many AM suppliers have strong engineering capabilities but immature quality management systems. They need significant guidance on AS9100 documentation requirements, not just technical assistance.

2023-01

Prepared for AS9100 Rev D recertification audit — gap analysis against current standard requirements, document updates for 23 quality procedures, and closure verification of 7 open CARs (Corrective Action Reports).

Challenge: Seven CARs had implementation evidence scattered across different departments with no central tracking. Had to personally verify implementation status with each department head in the 4 weeks before the audit.

Learned: CAR tracking must be centralized and status must be verifiable without visiting each department. Implemented a SharePoint-based CAR tracker with mandatory evidence upload as a result.