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 (setting)
- 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

📌 foundry quality manager (Sangli)
🏢 Veeresha Castings
📍 Sangli