Head Quality - Ferrous Foundry

Head Quality (Ferrous Foundry)

Department:

1. Position Objective

Quality function

2. Key Responsibilities

A. Quality Management Systems

• Develop, implement, and maintain integrated quality systems compliant with

  ISO 9001

  ,

  IATF 16949

  ,

  RDSO QAP

  , and

  IR/EN standards

  for railway and automotive sectors.
• Prepare and maintain

  Quality Assurance Plans (QAPs)

  and

  Process Flow Documents

  for various casting grades and customer requirements.
• Conduct internal audits and lead third-party / customer audits (RDSO, IR, automotive OEMs, etc.).
• Ensure system compliance and continual improvement through Management Review and corrective actions.

B. Supplier & Incoming Material Quality

• Define and monitor quality standards for

  pig iron, scrap, alloys, sand, binders, and refractories

  .
• Conduct vendor assessments, supplier audits, and incoming inspections to ensure material conformity.
• Lead supplier quality improvement programs focusing on consistency and traceability.

C. In-Process Quality Control

• Implement process controls in

  melting, molding, core making, pouring, fettling, and heat treatment

  stages.
• Establish

  standard operating parameters

  for railway and automotive castings.
• Conduct

  in-process audits

  ,

  process capability studies

  , and

  SPC monitoring

  for critical characteristics.
• Support production with real-time metallurgical and dimensional feedback.

D. Metallurgical & Laboratory Control

• Oversee metallurgical lab operations including

  spectrometer analysis

  ,

  microstructure examination

  ,

  hardness

  , and

  mechanical testing

  .
• Ensure heat-wise traceability and compliance with customer / RDSO chemical and mechanical requirements.
• Conduct metallurgical investigations,

  failure analysis

  , and

  root cause studies

  for internal and customer returns.

E. Dimensional & Visual Inspection

• Supervise

  CMM

  ,

  layout inspection

  , and

  gauging

  of castings as per drawings and control plans.
• Approve

  first-piece inspection reports

  and validate new product samples (PPAP / FAI).
• Implement visual inspection standards for surface finish, defects, and dimensional tolerances.

F. NDT (Non-Destructive Testing)

• Manage

  UT, MPI, DP, and Radiography

  inspections for critical railway and automotive components.
• Maintain qualified and certified NDT operators per

  ASNT / EN / IS

  standards.
• Ensure compliance with customer-specific and RDSO NDT procedures.

G. Customer Quality Interface

• Act as the primary interface with

  RDSO, Indian Railways, global railway OEMs

  , and

  automotive customers

  (Tier-1 suppliers or OEMs).
• Handle

  PPAP, FMEA, APQP, Control Plans, and MSA

  as per IATF 16949.
• Lead

  customer complaint resolution

  through 8D / RCA / CAPA methodologies.
• Coordinate with design and production teams for

  new product development and validation

  .

H. Continuous Improvement & Training

• Drive defect reduction and process capability improvement projects using

  Lean, Six Sigma, and Kaizen

  tools.
• Conduct internal quality and technical training programs for engineers, inspectors, and operators.
• Lead cross-functional quality improvement teams across melting, molding, and machining areas.

I. Compliance & Documentation

• Maintain compliance with

  RDSO

  ,

  IATF

  ,

  ISO

  , and

  statutory regulatory requirements

  .
• Ensure all calibration, testing, and inspection records are updated and traceable.
• Prepare monthly management reports covering rejections, PPM levels, audit results, and improvement actions.

3. Key Skills & Competencies

• Deep knowledge of

  ferrous metallurgy

  (grey iron, SG iron, cast steel).
• Strong exposure to

  Railway Quality Systems (RDSO QAP, wheel/axle casting standards)

  and

  Automotive Quality Systems (IATF 16949, PPAP, APQP, FMEA)

  .
• Expertise in

  casting defect analysis, metallurgical testing, and NDT methods

  .
• Proven ability to lead

  cross-functional teams

  and manage

  customer audits and approvals

  .
• Proficient in

  quality tools

  – 8D, SPC, MSA, FMEA, DOE, Six Sigma, and problem-solving techniques.
• Working knowledge of

  ERP/MES systems

  and digital quality dashboards.
• Strong leadership, analytical, communication, and interpersonal skills.