Quality Engineer - Foundry

Job Title

Key Responsibilities

1. Incoming Inspection

• Inspect raw materials, consumables, and customer-supplied parts.
• Ensure compliance with engineering drawings and specifications.
• Maintain accurate inspection records and reports.

2. Pattern & Tooling Inspection

• Inspect patterns, dies, and core boxes for new development projects.
• Verify dimensional accuracy as per drawings.
• Coordinate with design and production teams for corrections.

3. Casting Inspection

• Perform dimensional and visual inspection of aluminium sand castings and GDC components.
• Confirm casting soundness in ferrous and non-ferrous castings.
• Identify and record casting defects (porosity, shrinkage, inclusions, etc.).
• Conduct hardness testing (Brinell, Rockwell), density index testing, porosity testing, and spectro analysis.
• Review and analyze radiography test reports and films; provide corrective action guidance to process teams.

4. In-Process Quality Control

• Conduct stage-wise inspection during melting, pouring, and molding.
• Monitor furnace parameters, raw material mixing, and mold/core properties.
• Provide feedback and propose corrective actions for casting defects; track effectiveness.
• Support heat treatment process verification where applicable.

5. Vendor / Outsourcing Quality

• Perform in-process and final inspection at vendor sites.
• Ensure supplier compliance with quality standards and documentation.

6. Final Inspection & Dispatch

• Conduct final inspection of aluminium castings as per customer drawings and fixtures.
• Approve products for packing and dispatch.
• Ensure documentation for dispatch clearance.

7. Documentation & Reporting

• Prepare inspection reports, rejection analysis, and corrective action records.
• Control and maintain ISO quality documents.
• Analyze quality objectives data and present in BRM (Business Review Meeting) & MRM (Management Review Meeting).
• Support customer, internal, and external audits.
• Participate in quality improvement initiatives (CAPA, Kaizen, 5S, etc.).

Qualifications & Skills

• Diploma / B.E. in Mechanical, Metallurgy, or Production Engineering with relevant foundry experience.
• 35 years of experience in aluminium foundry quality assurance/inspection.
• Strong knowledge of aluminium sand casting and GDC processes.
• Experience in casting inspection, dimensional inspection, and soundness confirmation.
• Hands-on experience with spectro analysis, porosity testers, density index testers, and hardness testers (Brinell/Rockwell).
• Knowledge of radiography film analysis and corrective action support.
• Exposure to ISO documentation and quality systems.
• Knowledge of heat treatment process (preferred).
• Strong analytical, documentation, and communication skills.