Role Objective: To ensure heat treatment processes and product quality meet customer requirements, industry standards, and internal specifications. Responsible for maintaining process control, quality assurance, and continuous improvement in the heat treatment department. Key Responsibilities: Quality Assurance & Control Monitor and control all heat treatment processes (carburizing, nitriding, hardening, tempering, annealing, induction, etc.) to ensure compliance with specifications. Perform metallurgical inspections including hardness, microstructure, and case depth analysis. Approve heat treatment cycles, parameters, and reports in line with customer requirements. Ensure compliance with relevant standards (ISO, IATF, CQI-9,QMS, NADCAP if applicable). Conduct quality audits of heat treatment operations and documentation. Process & Equipment Validate furnace performance temperature uniformity surveys (TUS) and system accuracy tests (SAT). Ensure proper calibration of hardness testers, pyrometers, and other instruments. Support preventive maintenance of furnaces and equipment. Develop & optimize heat treatment cycles for new components. Customer & Compliance Address customer complaints related to heat treatment quality and provide effective corrective actions. Prepare and maintain process documentation (PFMEA, Control Plan, Work Instructions). Interface with customers and auditors during quality system audits and approvals. Continuous Improvement Implement statistical process control (SPC) and problem-solving methodologies (8D, RCA). Drive initiatives to reduce rejections, scrap, and rework. Support cost reduction projects through cycle optimization and energy efficiency. Key Skills & Competencies: Strong knowledge of metallurgical principles and heat treatment processes. Hands-on experience in microstructure analysis, hardness testing, and NDT methods. Proficiency in quality tools (APQP, PPAP, FMEA, SPC, MSA). Knowledge of CQI-9 (Heat Treatment System Assessment) and ISO/IATF standards. Problem-solving, analytical, and documentation skills. Strong interpersonal and communication skills for cross-functional and customer interaction. Qualifications & Experience: B.E. / B.Tech in Metallurgy / Mechanical Engineering (preferred Metallurgy). 58 years of experience in Heat Treatment Quality function in automotive / aerospace / precision components industry. Experience in CQI-9 compliance and customer audits preferred
Key Responsibilities: 1. Customer Drawing Study & Feasibility Analyze 2D/3D customer drawings, GD&T, and specifications . Conduct feasibility studies for manufacturability, process capability, and cost impact. Provide DFM (Design for Manufacturability) feedback to customers. 2. Process Planning & Flow Prepare process flow diagrams, operation sheets, and setup plans . Define machining sequences for CNC Turning, VMC, HMC, Grinding, and 5-axis machining . Identify special/critical characteristics and ensure process controls. 3. Tool Selection & Fixture Development Select cutting tools, inserts, tool holders based on component and material. Design and validate fixtures, jigs, and modular work-holding solutions . Optimize tooling layouts for reduced changeovers and cost efficiency . 4. CNC Programming (2D & 3D) Develop and optimize CNC programs for turning, VMC, HMC, and multi-axis machining. Generate 2D/3D toolpaths using CAM software ( UG NX, Mastercam, Creo, CATIA ). Validate CNC programs via simulation and prove-outs . Continuously improve cycle times, tool life, and machining efficiency . 5. Quality Tools & Validation Apply APQP, PPAP, PFMEA, Control Plan, MSA, and SPC in new development. Conduct First Article Inspection (FAI) and support customer PPAP sign-off. Ensure dimensional accuracy through CMM, profile, and surface measurements . Lead root cause analysis and corrective action for machining deviations. 6. Machining & Process Expertise Strong practical knowledge in CNC machining, VMC, HMC, grinding, and multi-axis machining . Expertise in cutting parameters for steels, aluminum, titanium, and super alloys . Troubleshoot issues like tool breakage, chatter, dimensional deviations, and finish defects . Drive lean initiatives : cycle time reduction, OEE improvement, tool cost optimization. 7. Team Management & Leadership Lead a team of manufacturing engineers, CNC programmers, and development engineers . Assign responsibilities, review performance, and ensure timely project execution. Mentor and train team members in process planning, CNC programming, tooling, and quality tools . Build competency in advanced machining, CAM software, and problem-solving techniques. Promote a culture of continuous improvement, accountability, and technical excellence . 8. Customer & Cross-functional Interface Act as the technical point of contact for customers during development. Collaborate with production, quality, and supply chain teams for smooth project handover. Support technical audits, customer reviews, and capability presentations