JOB DESCRIPTION – DEPUTY MANAGER – QUALITY ASSURANCE (GDC)1. Job Details

- Designation: Deputy Manager – Quality Assurance
- Department: Quality Assurance
- Process: Gravity Die Casting (GDC)
- Reports To: Quality Head / Plant Head
- Location: Manufacturing Plant
- Industry: Aluminium Die Casting / Automotive Components

2. Job Purpose

To lead and control Quality Assurance activities for Gravity Die Casting (GDC) operations, ensuring that products meet customer requirements, engineering specifications, applicable quality standards, and internal quality objectives. To drive defect prevention, process improvement, customer satisfaction, and continuous improvement throughout the manufacturing process.

3. Key ResponsibilitiesA. Quality Assurance & Process Control

- Lead Quality Assurance activities for all Gravity Die Casting operations.
- Ensure compliance with customer-specific requirements, drawings, specifications, and quality standards.
- Establish and monitor process control plans, inspection standards, and quality procedures.
- Monitor critical process parameters, including metal temperature, die temperature, pouring conditions, cooling time, and other process parameters as applicable.
- Ensure control of casting defects such as porosity, shrinkage, cold shuts, cracks, blowholes, inclusions, and dimensional variations.
- Monitor in-process inspection, final inspection, and product release activities.
- Ensure proper identification, segregation, and traceability of accepted, rejected, and rework materials.
- Verify the effectiveness of inspection methods and defect prevention controls.

B. Customer Quality Management

- Handle customer complaints and coordinate timely corrective and preventive actions.
- Prepare and submit 8D reports, root cause analysis, and corrective action reports.
- Coordinate customer audits, process audits, product audits, and quality reviews.
- Monitor customer rejection, PPM, warranty issues, and customer satisfaction performance.
- Ensure implementation of customer-specific quality requirements.
- Coordinate with customers for quality approvals, sample submissions, and validation activities.
- Ensure effective implementation and closure of customer audit findings.

C. Quality Systems & Documentation

- Maintain and improve the Quality Management System in accordance with applicable IATF 16949 and ISO 9001 requirements.
- Review and maintain PFMEA, Control Plan, Process Flow Diagram, inspection standards, and work instructions.
- Ensure implementation of APQP, PPAP, MSA, SPC, FMEA, and other applicable core quality tools.
- Monitor document control, calibration records, inspection reports, and quality records.
- Plan and conduct internal process audits, product audits, and system audits.
- Coordinate external audits, certification audits, and customer assessments.




- Ensure timely closure of non-conformities and verification of corrective action effectiveness.

D. Inspection & Testing

- Ensure effective inspection of incoming raw materials, in-process components, and finished products.
- Monitor dimensional inspection, chemical composition, mechanical testing, metallurgical testing, and other applicable tests.
- Ensure proper utilization and calibration of measuring instruments and testing equipment.
- Coordinate CMM, spectrometer, hardness testing, tensile testing, and other laboratory activities as applicable.
- Ensure validation of inspection methods and reliability of measurement systems.
- Review inspection results and approve products as per defined authority and procedures.

E. Non-Conformance & Continuous Improvement

- Lead root cause analysis using 5 Why, Fishbone Diagram, 8D, and other problem-solving techniques.
- Implement corrective and preventive actions to eliminate recurring defects.
- Drive reduction in internal rejection, customer rejection, rework, scrap, and Cost of Poor Quality (COPQ).
- Monitor quality performance through KPIs, trend analysis, and periodic reviews.
- Lead Kaizen, Poka-Yoke, process improvement, and defect prevention initiatives.
- Ensure effective control of non-conforming products and prevent unintended use or dispatch.
- Conduct periodic defect analysis and communicate improvement actions to relevant departments.

F. Team Management & Training

- Lead, guide, and develop Quality Engineers, Quality Inspectors, and laboratory personnel.
- Prepare departmental objectives, manpower plans, and training schedules.
- Conduct training on quality standards, casting defects, inspection methods, and problem-solving techniques.
- Evaluate employee competency and training effectiveness.
- Ensure adherence to safety, 5S, discipline, and standard operating procedures within the Quality Department.
- Coordinate with Production, Maintenance, Tool Room, and other departments to resolve quality issues.

G. Supplier & Cross-Functional Coordination

- Coordinate with suppliers for raw material and component quality issues.
- Support supplier audits, corrective actions, and supplier performance improvement.
- Work closely with Production and Process Engineering to maintain stable manufacturing processes.
- Coordinate with Maintenance and Tool Room teams to resolve die-related and machine-related quality issues.
- Participate in new product development, trial runs, process validation,



and production approval activities.
- Review process changes and ensure appropriate quality validation before implementation.

4. Key Performance Indicators (KPIs)

- Internal rejection and scrap percentage.
- Customer rejection and customer PPM.
- First Pass Yield (FPY).
- Rework and Cost of Poor Quality (COPQ).
- Customer complaint response and closure time.
- Audit non-conformity closure effectiveness.
- Process audit and product audit compliance.
- Calibration compliance of measuring instruments.
- On-time PPAP and quality documentation submission.
- Reduction in recurring casting defects.
- Training completion and competency improvement.
- Kaizen and continuous improvement achievements.

5. Educational Qualification

- Bachelor’s Degree or Diploma in Mechanical Engineering, Metallurgy, Production Engineering, or a relevant engineering discipline.
- Additional quality management qualifications will be an advantage.

6. Experience

- Typically 7–10 years of experience in Quality Assurance in manufacturing, preferably in aluminium Gravity Die Casting or automotive component manufacturing.
- Relevant experience in a quality leadership role is preferred.
- Experience in customer handling, casting defect analysis, quality systems, and cross-functional coordination is essential.

7. Technical Skills

- Strong knowledge of Gravity Die Casting processes and aluminium casting defects.
- Knowledge of IATF 16949, ISO 9001, and customer-specific requirements.
- Practical knowledge of APQP, PPAP, PFMEA, Control Plan, SPC, MSA, and 8D.
- Knowledge of GD&T;, engineering drawings, dimensional inspection, and metrology.
- Experience with root cause analysis, corrective action, and defect prevention.
- Knowledge of statistical analysis, quality reporting, and KPI monitoring.
- Proficiency in MS Excel, PowerPoint, Word, and quality reporting systems.

8. Behavioural Competencies

- Leadership and team management.
- Analytical and problem-solving skills.
- Solid communication and customer-handling skills.
- Decision-making and accountability.
- Cross-functional coordination.
- Planning, prioritization, and execution.
- Continuous improvement mindset.

9. Authority & Accountability

- Authority to recommend or initiate product and process containment for quality concerns.
- Authority to identify, segregate, and control non-conforming products as per company procedures.
- Responsibility for escalation of critical quality issues and prevention of defective product dispatch.
- Accountability for departmental quality objectives, audit compliance, customer satisfaction, and continuous improvement.

Pay: ₹60,000.00 per month

Benefits:

- Cell phone reimbursement
- Flexible schedule
- Food provided
- Paid sick time
- Provident Fund

Work Location: In person

📌 Deputy Manager - Quality Assurance (Hosur)
🏢 APJ TECHNOCAST PRIVATE
📍 Hosur