Head – Quality Assurance (Foundry)

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

1. 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

1. 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

1. 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

1. 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

1. 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

• Strong 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