foundry quality manager

Veeresha Castings; Sangli District; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Veeresha Castings is seeking a Quality Assurance Manager to lead the Quality Management System and drive process quality across melting, molding, core making, pouring, and finishing operations. You will oversee inspections, testing, CAPA, and cross-functional quality initiatives.

The role requires deep metallurgical knowledge, DFMEA/PPAP experience, and strong leadership to mentor the QA team and coordinate with production and procurement. On-site in Maharashtra, India.

Qualifications

• Deep knowledge of casting processes and metallurgy.
• Experience with GD&T and engineering drawings.
• Proficient in Root Cause Analysis and CAPA.
• Strong command of SPC, MSA, PFMEA, and PPAP.

Responsibilities

• Lead QMS development and audits across functions.
• Oversee process quality control and capability.
• Manage inspections: incoming, in-process, final, and testing.
• Address customer complaints and coordinate audits.
• Qualify and evaluate suppliers; drive supplier quality.
• Analyze defects and reduce CPPQ costs and defects.
• Drive continuous improvement using Lean, Six Sigma, Kaizen, and DOE.
• Maintain documentation: SOPs, control plans, PPAP, PFMEA.
• Lead quality team and set KPIs; train staff.
• Monitor FPY, rejection rates, rework, and scrap costs.
• Coordinate cross-functional efforts to resolve quality issues.

Skills

Casting processes

Metallurgy

GD&T

Root Cause Analysis

SPC

MSA

PFMEA

PPAP

ISO 9001

Leadership

ERP QA software

Data analysis

Tools

Minitab

Quality management software

Job description

Key Roles and Responsibilities

1. Quality Management System (QMS)

• Develop, implement, and maintain the Quality Management System.
• Ensure compliance with standards such as:
  • ISO 9001
  • IATF 16949 (automotive)
  • ISO 14001 (environment)
  • ISO 45001 (occupational health & safety), where applicable.
• Lead internal and external quality audits.

2. Process Quality Control

• Establish quality control plans for:
  • Melting
  • Molding
  • Core making
  • Pouring
  • Fettling
  • Heat treatment
  • Machining (if applicable)
• Monitor critical process parameters and ensure process capability.

3. Inspection and Testing

• Manage incoming, in-process, and final inspection activities.
• Oversee:
  • Chemical analysis
  • Sand testing
  • Mechanical testing
  • Dimensional inspection
  • Visual inspection
  • Non-destructive testing (UT, RT, MPI, DPI)
  • Metallography.

4. Customer Quality Management

• Address customer complaints using structured problem-solving tools.
• Lead:
  • 8D Reports
  • Root Cause Analysis
  • Corrective and Preventive Actions (CAPA)
• Coordinate customer audits and visits.
• Improve customer satisfaction and reduce PPM (Parts Per Million defects).

5. Supplier Quality

• Qualify and evaluate suppliers.
• Monitor supplier performance.
• Conduct supplier audits.
• Drive supplier quality improvement initiatives.

6. Defect Analysis

Analyze and reduce defects such as:

• Blowholes
• Shrinkage
• Cold shuts
• Misruns
• Sand inclusions
• Slag inclusions
• Hot tears
• Porosity
• Dimensional variation.

7. Continuous Improvement

Lead improvement initiatives using:

• Lean Manufacturing
• Six Sigma
• Kaizen
• Poka-Yoke
• Statistical Process Control (SPC)
• Failure Mode and Effects Analysis (FMEA)
• Design of Experiments (DOE).

8. Quality Documentation

Maintain:

• Control Plans
• Inspection standards
• Standard Operating Procedures (SOPs)
• Work Instructions
• PPAP documentation
• Process Flow Diagrams
• PFMEA
• Quality records
• Calibration records.

9. Team Leadership

• Lead quality engineers, inspectors, and laboratory personnel.
• Set KPIs and performance targets.
• Conduct training on quality tools and standards.
• Develop succession plans and mentor team members.

10. KPI Monitoring

Track and improve:

• First Pass Yield (FPY)
• Rejection rate
• Rework rate
• Scrap cost
• Customer PPM
• Cost of Poor Quality (COPQ)
• Internal defect rate
• On-time closure of CAPA
• Supplier PPM
• Audit findings.

11. Cross-functional Coordination

Collaborate with:

• Production
• Process Engineering
• Maintenance
• Purchase
• Design
• Tool Room
• Sales
• Customer Support
  to resolve quality issues and improve manufacturing performance.

12. Compliance and Risk Management

• Ensure compliance with customer-specific requirements.
• Maintain calibration systems.
• Ensure traceability of materials and products.
• Support regulatory and statutory compliance.

Essential Skills

• Deep knowledge of casting processes (Grey Iron, SG Iron, Steel, Aluminum, etc.)
• Metallurgy and material science
• GD&T and engineering drawings
• Root Cause Analysis (5 Why, Fishbone)
• SPC and statistical analysis
• MSA (Measurement System Analysis)
• PFMEA and Control Plans
• APQP and PPAP
• ISO 9001 and IATF 16949
• Problem-solving and decision-making
• Leadership and communication
• ERP and quality management software
• Data analysis using Excel, Minitab, or similar tools