Deputy Welding Manager

Bull Machines; Coimbatore District; On-site; INR 600,000 - 1,000,000; Full time

Job summary

Bull Machines in India seeks a Welding Quality Engineer to ensure the quality and reliability of welded components and fabricated structures for backhoe loaders. You will control welding processes, inspect welds, manage NDT coordination, and drive continuous improvement to achieve zero defects.

You will supervise welding quality engineers and technicians, ensure compliance with WPS/PQR, and coordinate with suppliers and internal teams to reduce rejection, rework, and COPQ.

Qualifications

• Experience or knowledge in welding quality control and inspection.
• Familiarity with WPS/PQR and welding standards is helpful.

Responsibilities

• A. Welding Process Quality Control: Ensure compliance with WPS/PQR; monitor welding parameters; ensure joint prep, fit-up, root gap, tack welding, weld sequence and distortion control; verify welder qualification and machine calibration; monitor weld quality of critical components.
• B. Welding Inspection and Testing: Establish inspection stages for incoming parts, in-process welding and final welds; identify defects such as cracks or porosity; ensure dimensional accuracy per drawings; coordinate NDT activities; review test results and weld records.
• C. Supplier and Fabrication Quality: Conduct process audits at suppliers; evaluate supplier welding capabilities and inspection facilities; review APQP/PPAP/WPS/PQR; monitor rejection and rework; drive corrective actions.
• D. Non-Conformance and CAPA: Lead root-cause analyses; contain defects; implement permanent corrective actions; implement interlocks and fixture improvements; track COPQ.
• E. Team Management and Continuous Improvement: Supervise weld quality team; prepare skill matrices and training; conduct audits and daily meetings; collaborate with cross-functional teams; lead improvement projects.

Job description

Job Purpose

To ensure the quality and reliability of all welded components and fabricated structures used in backhoe loaders, including boom, dipper arm, loader arms, chassis, stabilizer legs, buckets, brackets and other structural assemblies. The role is responsible for welding process control, weld inspection, defect prevention, supplier quality, weld laboratory activities, and continuous improvement to achieve Zero Defect, Zero Rework and customer satisfaction.

Roles and Responsibilities

A. Welding Process Quality Control

• Ensure compliance with approved Welding Procedure Specifications (WPS) and applicable Procedure Qualification Records (PQR).
• Monitor welding parameters such as current, voltage, wire feed speed, travel speed, gas flow and heat input, where applicable.
• Ensure proper joint preparation, fit-up, root gap, tack welding, weld sequence and distortion control.
• Verify welder qualification, operator competency and welding machine calibration.
• Monitor weld quality of critical structural components such as boom, dipper, loader arms, chassis and stabilizer assemblies.

B. Welding Inspection and Testing

• Establish inspection stages for incoming fabricated parts, in-process welding and final welded assemblies.
• Identify and control weld defects such as cracks, porosity, undercut, lack of fusion, incomplete penetration, overlap and excessive spatter.
• Ensure dimensional accuracy, weld size, throat thickness and structural geometry as per approved drawings.
• Coordinate NDT activities such as MPI, DPI, UT and RT wherever specified.
• Review destructive test results, macro-etch reports and weld qualification records where applicable.

C. Supplier and Fabrication Quality

• Conduct process audits at fabrication and welding suppliers.
• Evaluate supplier capability for welding processes, fixtures, jigs, equipment, skilled manpower and inspection facilities.
• Review supplier APQP, PPAP, PFMEA, Control Plans, WPS/PQR and welder qualification records.
• Monitor supplier rejection PPM, repeat defects, rework and delivery-related quality issues.
• Drive supplier corrective actions and verify effectiveness before closure.

D. Non-Conformance and CAPA

• Lead root-cause analysis using 4M+1E, 5 Why, Fishbone and 8D methodologies.
• Ensure immediate containment of defective welded components and prevent unintended use or dispatch.
• Establish permanent corrective and preventive actions for recurring weld defects.
• Implement mistake-proofing, fixture improvements and parameter interlocks wherever feasible.
• Track internal rejection, rework hours, customer complaints and Cost of Poor Quality (COPQ).

E. Team Management and Continuous Improvement

• Supervise welding quality engineers, inspectors and technicians.
• Prepare skill matrices and arrange training on weld defects, inspection methods, drawing interpretation and standards.
• Conduct layered process audits, weld quality reviews and daily performance meetings.
• Collaborate with Production, Manufacturing Engineering, NPD, Maintenance, Supplier Quality and R&D teams.
• Lead quality improvement projects to reduce rejection, rework, cycle time and COPQ.