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Nicholas Sarahs
AXMINSTER,Devon
Summary
Highly experienced and capable manager specialising in engineering for the Aerospace, Space, Defence, Medical Devices and Automotive industries. My company "AeroQual Consultants Ltd" is driven by my client's success and can assist at many levels of operation to enhance design, manufacturing, quality and output. For over 40 years I have been highly successful in augmenting and developing quality and business management systems, innovating manufacturing techniques, Improvement in operational delivery, enhancing on time customer satisfaction and profit. I possess a strong expertise in project management, process improvement, product transfer, and NPI across global operations and smaller business concerns. I am an experienced consultant with a reputation for delivering zero-defect production, regulatory compliance, and significant process efficiencies. I can provide a proven record in implementing and maintaining AS9100, ISO9001, ISO13485 systems, NADCAP special process certification, and FAA/CAA and EASA conformity.
Overview
46
46
years of professional experience
Work History
Director and Owner
AeroQual Consultants Ltd
AXMINSTER, Devon
08.2024 - Current
- Assisting client "Parker Hannifin in the creation, development and functioal processing of a supply chain validation systems to support a global supplier change project.
Quality Manager UK and US
Solid State Supplies Ltd
Weymouth
02.2022 - 08.2024
- Creation and implementation of a complete quality management system to support the introduction of medical devices (ISO 13485) and aerospace (AS 9100) design, development, and manufacture throughout the group.
- Day-to-day running of quality management to support quality assurance and control teams and processes across the design and development, quality, and manufacturing teams for three plants, two in the UK and one in the US.
CEO
LymeForward CIC
Lyme Regis
04.2021 - 11.2021
- Contractually employed during the COVID crisis to develop operating and quality systems for this small charitable organisation, creating acceptable alignment with charity regulations and practices.
Owner
Aerospace Quality Consultants
AXMINSTER, Devon
01.2020 - 01.2021
- Primary project for "Smiths Harlow" in London to drive and manage a manufacturing relocation project, including the complete transfer of product, plant, personnel, and logistics. This contract was terminated due to the cancellation of the project because of COVID shutdown.
- Day-to-day running of quality management to support quality assurance, control teams, and processes.
Operations Manager
Southwest Metal Finishing Ltd
Exeter, Devon
08.2019 - 12.2019
- Collaberation to assist with NADCAP compliance issues in chemical processing controls in both manufacturing and systems . Projects were identified to solve compliance issues; however, there was non-alignment in direction.
Quality Manager
FGP Lufton Ltd
Yeovil, Somerset
08.2017 - 08.2019
- The primary role was to develop a business and quality management system for a startup factory supplying the aerospace industry. The scope included AS9100, ISO 9001, and NADCAP certification for machining, NDT, welding, and heat treatment processes. This was completed successfully, with only minor findings at the audit.
Technologist Lead in NDT and Advanced Metrology
GKN Aerospace
Bristol, Bristol UK
11.2016 - 08.2017
- Project Management
- Design and development of the Airbus Automated Wing Rib Metrology System.
- Managing a technology team, seeking to develop and exploit new and emerging technologies in NDT and advanced metrology to the advantage of the GKN production facility at Filton, Bristol, UK.
- My project responsibility was to deliver the "Airbus Wing Rib Automated Metrology System" on a budget of £1.8M.
- Initiate, develop, and deliver innovations and tangible practices that bring value-added processes to the production facility, co-opting the assistance of subject specialists and stakeholders, in Bristol.
- Collaboration with external specialist metrology design sources (Insphere Ltd).
- Downselection of over 20 possible system types.
UK Quality Manager
Gooch & Housego Ltd
09.2015 - 11.2016
- Responsible for the enhacement of existing ISO9001 quality management system enabling compliance and certification of aerospace AS9100 design and manufacturing capability.
- Successfully completed and implimented.
- Day-to-day running of quality management to support quality assurance and control teams and processes across the design and development, quality, and manufacturing teams for two plants, in England and Scotland.
Principal Quality Engineer
United Technologies Aerospace Systems
Bristol, Bristol UK
02.2008 - 09.2015
- Successfully completed four design and development projects as a quality lead, including the Boeing 787-8, 787-9, Sikorsky S92, CH53, and M60 Blackhawk.
- My work on the 787 and S92 projects saw me develop the complete FAA conformity system to comply with FAA regulations, as well as Boeing and Sikorsky requirements. These were managed well and delivered in a timely manner with little or no issues. The FAA representative at Boeing reported that the work carried out and presented by Claverham was world-class and recorded an MFA score of 7 out of 7.
- In December 2013, I was deployed to the Claverham Surface Finishing Treatments facility, where, in 2012, several problems existed that impacted customer satisfaction. I was tasked with improving quality and on-time delivery through increased production capacity. This was achieved within six months, with customer satisfaction scores of 6.33 out of 7.
- Improvements in chemical processing and NDT activity culminated in NADCAP approval for both.
- In February 2015, I was asked to investigate paint adhesion issues being encountered on Boeing 787 interiors by Susan Bartelli, Quality Authority for Boeing programmes. The problems at an interior lighting supplier within the UTAS group had been causing issues for over nine months with no solution. After assessing the conditions and causes, I was able to advise on several actions that successfully solved the failure within one month. This was described by Susan as “incredible news” and a “great success of collaboration.”
- General day-to-day quality activities for the smooth operation of the business, design, and manufacturing teams.
Process and Project Engineer / Quality Engineer
Doncasters: Chard Ltd
01.2004 - 02.2008
- Originally drafted on a contract to assist with the final inspection.
- It very quickly became clear that rework and scrap levels were very high, especially in fettling, wax forming, and shelling processes.
- Employed as a Process and Quality Engineer to resolve issues in manufacturing. The introduction of detailed process control, QCPC, SPC, training systems, and lean six sigma practices saw defects reduce from 48% by volume of parts to under 6% within six months.
Quality, Manufacturing and Logistical supervisor
General Meat Industry
UK, UK
01.1987 - 01.2004
- For several years, I moved from the engineering industry and requalified in microbiology to work in the meat manufacturing industry.
- Engagements were with St Meryn Meat in Cornwall, Dalehead Foods in Bristol, Key Country Foods in Scunthorpe, and Romford Meats in Yeovil.
- This involved me in quality supervision, the running of quality and microbiological labs, manufacturing supervision, and logistical management.
Apprentice and Jig & Tool Designer
Rolls Royce Ltd
01.1980 - 01.1986
- Successfully completed an apprenticeship at the Bristol site, specialising in special purpose machining, and jig and tool design.
- Design and development of tooling, fixtures, and process procedures to produce aero-engine components.
- Programming and operation of CNC, NC, and manually controlled machinery.
Education
Continuous Business Improvement – Management and Cultural awareness strategies in the workplace.
University of Humberside
Hull UK1999
Technical Diploma - Mechanical & Production Engineering
Filton Technical College
Briistol UK1986
Technical Diploma - Mechanical & Production Engineering
Rolls Royce Technical College
Bristol UK01.1986
Skills
- Quality and business management systems
- Continuous improvement
- Analytical skills
- Root cause analysis
- 8D problem solving
- Lean Six Sigma methodology
- Process engineering
- Engineering change control
- Calibration management
- Process improvement
- Systems enhancement
- Quality training and auditing
- Product transfer management
- Metrology services
- Validation and verification services
- Engineering control projects
- Technical documentation
- Strategic planning
- Process optimization
- Performance metrics tracking
- Executive communication
- Operations management
- Supply chain optimization
- Regulatory compliance knowledge
- Programme oversight
- Policy enforcement
Interests
Timeline
Director and Owner
AeroQual Consultants Ltd
08.2024 - Current
Quality Manager UK and US
Solid State Supplies Ltd
02.2022 - 08.2024
CEO
LymeForward CIC
04.2021 - 11.2021
Owner
Aerospace Quality Consultants
01.2020 - 01.2021
Operations Manager
Southwest Metal Finishing Ltd
08.2019 - 12.2019
Quality Manager
FGP Lufton Ltd
08.2017 - 08.2019
Technologist Lead in NDT and Advanced Metrology
GKN Aerospace
11.2016 - 08.2017
UK Quality Manager
Gooch & Housego Ltd
09.2015 - 11.2016
Principal Quality Engineer
United Technologies Aerospace Systems
02.2008 - 09.2015
Process and Project Engineer / Quality Engineer
Doncasters: Chard Ltd
01.2004 - 02.2008
Quality, Manufacturing and Logistical supervisor
General Meat Industry
01.1987 - 01.2004
Apprentice and Jig & Tool Designer
Rolls Royce Ltd
01.1980 - 01.1986
Continuous Business Improvement – Management and Cultural awareness strategies in the workplace.
University of Humberside
Technical Diploma - Mechanical & Production Engineering
Filton Technical College
Technical Diploma - Mechanical & Production Engineering
Rolls Royce Technical College