Job Description:

Job Title: Head – Quality Assurance (Foundry)

Department: Quality

Location: Belgaum

Reporting to: Plant Head

Job Purpose

To lead and manage the Quality Assurance function for Cast Iron Foundry operations, ensuring consistent production of high-quality castings through robust systems, process controls, customer compliance, and continuous improvement — specifically for No-Bake molding process and critical automotive components like Cylinder Heads and Engine Blocks.

Key Responsibilities

1. Quality Systems & Compliance

- Establish, implement and maintain QMS in line with ISO 9001 / IATF 16949 standards
- Ensure adherence to customer specifications, APQP, PPAP, MSA, SPC, FMEA
- Lead internal audits, customer audits and certification activities

2. Process Quality – No Bake Foundry

- Control and improve No-Bake molding, melting, pouring, shakeout, fettling and inspection processes
- Monitor sand properties, resin systems, mold strength and defect prevention
- Drive reduction of casting defects such as blow holes, shrinkage, cold shuts, inclusions, misruns

3. Product Quality – Cylinder Head & Block

- Ensure dimensional, metallurgical and functional quality of critical engine components
- Oversee NDT (UT, MPI, X-ray where applicable), microstructure analysis, hardness testing
- Ensure conformance to automotive OEM standards

4. Customer Interface





- Handle customer complaints, root cause analysis (8D), corrective & preventive actions
- Lead customer visits, audits and quality reviews
- Ensure zero PPM mindset and customer satisfaction

5. Team Leadership

- Lead QA/QC, lab, inspection and supplier quality teams
- Develop quality culture across foundry operations
- Train manpower on defect prevention and quality tools

6. Continuous Improvement

- Implement Lean, Six Sigma and defect reduction projects
- Drive cost of poor quality (COPQ) reduction
- Improve process capability and yield

Qualifications

- BE/BTech – Metallurgy / Mechanical / Production Engineering
- Certification in Quality Systems / Six Sigma preferred

Experience

- 18+ years in Cast Iron Foundry Quality
- Mandatory experience in:

- No-Bake molding process
- Automotive castings – Cylinder Heads & Engine Blocks
- Customer quality systems (OEMs/Tier-1)

Key Skills & Competencies

- Robust knowledge of CI metallurgy (SG Iron / Grey Iron as applicable)
- Casting defect analysis & prevention
- IATF 16949, APQP, PPAP, SPC, MSA
- NDT & metallurgical testing
- Leadership & cross-functional coordination
- Customer handling & audit management

Performance Indicators (KPIs)

- PPM reduction
- Customer complaints closure
- Process capability (Cp/Cpk)
- Yield improvement
- Audit scores

📌 Hiring for Head – Quality Assurance (Foundry) (Belagavi)
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