Foundry Quality Manager

The Foundry Quality Manager will be responsible for planning, implementing, and maintaining quality assurance systems across the foundry operations. The role ensures compliance with customer specifications, internal quality standards, and relevant ISO/automotive quality systems. The position involves leading the quality team, reducing rejections, handling customer audits, and driving continuous improvement initiatives.

Key Responsibilities

Quality Management & Assurance

• Develop, implement, and maintain Quality Management Systems (QMS) in line with ISO 9001 / IATF 16949 (if applicable).
  
• Ensure adherence to quality standards for raw materials, molding, melting, pouring, fettling, heat treatment, and final inspection.
  
• Establish and monitor process controls to minimize defects and rejections.
  
• Define inspection standards, control plans, and quality checkpoints across the foundry.
  

Customer Quality & Audits

• Handle customer complaints, rejections, and corrective/preventive actions (CAPA).
  
• Lead customer audits, third-party audits, and certification audits.
  
• Ensure timely submission of quality documents such as PPAP, APQP, FMEA, Control Plans, and Inspection Reports (as applicable).
  
• Maintain strong coordination with customers for quality expectations and improvements.
  

Process Improvement

• Analyze internal and external rejection data and implement root cause analysis (RCA) using tools like 7 QC tools, Fishbone, 5 Why, etc.
  
• Drive continuous improvement initiatives to reduce casting defects such as porosity, sand inclusion, shrinkage, cracks, etc.
  
• Work closely with production, melting, molding, and maintenance teams to improve process capability.
  

Team Leadership & Training

• Lead, mentor, and develop the quality team including inspectors and engineers.
  
• Conduct regular training programs on quality standards, inspection techniques, and problem-solving tools.
  
• Foster a culture of quality awareness across all departments.
  

Documentation & Compliance

• Maintain all quality-related documentation, SOPs, work instructions, and records.
  
• Ensure calibration and maintenance of measuring instruments and testing equipment.
  
• Monitor compliance with safety, environmental, and statutory quality requirements.
  

Vendor & Incoming Quality

• Monitor incoming raw material quality (pig iron, scrap, sand, additives, etc.).
  
• Work with suppliers to improve material quality and consistency.
  
• Conduct supplier audits and evaluations as required.
  

Key Skills & Competencies

• Strong knowledge of foundry processes (Green Sand / No-Bake / Shell Molding as applicable).
  
• In-depth understanding of casting defects and corrective actions.
  
• Hands-on experience with metallurgical testing and inspection methods.
  
• Knowledge of ISO 9001 / IATF 16949 standards.
  
• Proficiency in quality tools: APQP, PPAP, FMEA, SPC, MSA, 7 QC Tools.
  
• Good leadership, communication, and coordination skills.
  
• Ability to analyze data and drive continuous improvement.
  

Educational Qualifications

• Bachelors Degree in Mechanical / Metallurgical / Production Engineering.
  
• Additional certification in Quality Management Systems preferred.
  

Experience Requirements

• 7 to 12 years of relevant experience in foundry quality management.
  
• Prior experience in automotive or engineering casting foundries preferred.
  
• Experience handling customer audits and large OEM customers is an advantage.
  

Key Performance Indicators (KPIs)

• Reduction in internal and external rejection levels.
  
• Customer complaint closure time.
  
• Audit scores and compliance levels.
  
• Improvement in process capability and yield.
  
• Team performance and training effectiveness.