Job Description (JD) – Foundry Quality Manager (CI & SG Iron Foundry)Job Title
Foundry Quality Manager
Department
Quality Assurance (Foundry)
Reports To
Plant Head / Unit Head
Location
Manufacturing Plant (CI & SG Iron Foundry)
Qualification
- B.E./B.Tech in Metallurgy / Mechanical Engineering
- Diploma in Metallurgy (for experienced candidates)
- Lead Auditor (ISO 9001/IATF 16949) preferred
- Six Sigma Green Belt/Black Belt will be an added advantage
Experience
- 10–15 years of experience in Grey Iron (CI) & SG Iron Foundry Quality Management.
- Experience in Automotive, Agriculture, Railway, Valve, Pump, or Engineering Casting Industry preferred.
Job Purpose
To lead the Quality Assurance function by ensuring that all CI & SG Iron castings meet customer specifications and international quality standards through effective quality systems, process control, laboratory management, defect prevention, customer complaint resolution, and continuous improvement initiatives. The role typically oversees laboratory testing, casting defect analysis, customer quality, and compliance with ISO/IATF requirements. (Farrar Corporation)
Key Responsibilities1. Quality Management
- Develop and implement quality policies and procedures.
- Ensure compliance with ISO 9001, IATF 16949, customer standards, and internal quality systems.
- Maintain Quality Management System documentation.
- Conduct Management Review Meetings.
2. Incoming Quality Control
- Approve incoming raw materials including:
- Pig Iron
- Steel Scrap
- Ferro Alloys
- Inoculants
- Magnesium
- Sand
- Bentonite
- Resins
- Coatings
- Ensure supplier quality compliance.
3. Process Quality Control
Monitor and control quality during:
- Pattern Inspection
- Core Making
- Sand Testing
- Moulding
- Melting
- Metal Chemistry
- SG Treatment
- Inoculation
- Pouring
- Shakeout
- Fettling
- Shot Blasting
- Heat Treatment
- Final Inspection
4. Metallurgical Laboratory Management
Ensure proper functioning of:
- Spectrometer
- Thermal Analysis
- Sand Laboratory
- Metallography
- Hardness Testing
- Tensile Testing
- Chemical Analysis
- Microstructure Evaluation
Review laboratory reports and approve production.
5. Casting Defect Analysis
Lead investigation and corrective action for:
- Blow Holes
- Sand Inclusion
- Shrinkage
- Misrun
- Cold Shut
- Slag Inclusion
- Pin Holes
- Gas Porosity
- Hard Spot
- Graphite Defects
- Chill
- Scab
- Crack
- Mismatch
- Dimensional Issues
Use:
- 8D
- Fishbone
- 5 Why
- Pareto Analysis
- FMEA
6. Customer Quality Management
- Handle customer complaints.
- Lead root cause analysis.
- Prepare 8D reports.
- Attend customer quality meetings.
- Coordinate customer audits.
- Ensure customer satisfaction.
- Monitor warranty and rejection trends.
7. Quality Documentation
Maintain:
- Control Plans
- PFMEA
- Process Flow Diagram
- SOP
- Work Instructions
- PPAP Documents
- APQP Documents
- Inspection Reports
- Calibration Records
- Traceability Records
8. Inspection Management
Ensure:
- First Piece Inspection
- In-process Inspection
- Final Inspection
- Layout Inspection
- Gauge Control
- Calibration
- NDT Inspection (if applicable)
- Visual Inspection
- Dimensional Inspection using CMM & gauges
9. Supplier Quality
- Conduct supplier audits.
- Develop supplier quality improvement plans.
- Approve new suppliers.
- Monitor supplier PPM.
- Resolve supplier quality issues.
10. Audit Management
Lead:
- Internal Audits
- Customer Audits
- ISO Audits
- IATF Audits
- Process Audits
- Product Audits
- Layered Process Audits
11. Continuous Improvement
Drive:
- Kaizen
- Lean Manufacturing
- Six Sigma Projects
- Cost Reduction
- Scrap Reduction
- Rework Reduction
- Yield Improvement
- Right First Time (RFT)
- Zero Defect Initiatives
12. Team Management
- Lead Quality Engineers
- Metallurgists
- Lab Technicians
- Quality Inspectors
- Final Inspectors
- Shift Quality Team
Conduct:
- Training
- Skill Development
- Performance Reviews
- Daily Quality Meetings
Key Performance Indicators (KPIs)KPITargetCustomer PPM< 500 PPM (or customer requirement)Internal Rejection< 2%Customer ComplaintsZero Major ComplaintsFirst Pass Yield> 98%Right First Time> 98%CAPA Closure100% within target dateSupplier Rejection< 1%Calibration Compliance100%Audit Compliance100%PPAP Approval100% On TimeScrap ReductionYear-on-Year ImprovementCost of Poor QualityContinuous ReductionOn-Time Laboratory Reports100%Training Completion100%Technical Skills
- Grey Iron (CI) & SG Iron Metallurgy
- Green Sand / No-Bake / Shell Moulding Process
- Spectrometer Operation
- Thermal Analysis
- Sand Testing
- Metallography
- APQP
- PPAP
- FMEA
- SPC
- MSA
- Control Plan
- 8D
- Root Cause Analysis
- CMM
- GD&T
- ISO 9001
- IATF 16949
- ERP/SAP
- Microsoft Excel & Power BI
Behavioral Competencies
- Leadership
- Decision Making
- Analytical Thinking
- Customer Focus
- Problem Solving
- Team Management
- Communication Skills
- Continuous Improvement Mindset
- Result Orientation
- Planning & Organizing
Reporting Team
- Deputy Manager – Quality
- Quality Engineers
- Metallurgist
- Laboratory In-charge
- Quality Inspectors
- Final Inspectors
- CMM Engineer
- Documentation Engineer
Pay: ₹45,000.00 - ₹70,000.00 per month
Benefits:
- Health insurance
- Leave encashment
- Life insurance
- Provident Fund
Work Location: In person
