Supplier Quality & Development Engineer – Castings & Machining

The Supplier Quality & Development Engineer (SQDE) is responsible for ensuring the quality and continuous development of suppliers involved in casting and machining processes. This role supports new product introductions (NPI), manages supplier quality issues, and drives improvement initiatives across the supply base. The SQDE acts as a technical liaison between suppliers and internal teams including design, sourcing, manufacturing, and global quality.

Key Responsibilities:

Supplier Quality Assurance

• Manage day-to-day supplier quality issues and ensure robust containment on production lines.
• Issue NCRs and lead root cause analysis (RCA) and 8D problem-solving with suppliers.
• Develop and implement containment methods, SOPs, and quality plans for supplier PDAs and inspections.
• Lead MRB processes and manage disposition of non-conforming parts.
• Monitor and report supplier performance (PPM, NCRs, FTT).
• Support QMS compliance during customer and IATF audits.
• Deliver supplier training on quality awareness, Q-alerts, and risk assessments.

Supplier Development & Qualification

• Evaluate and develop supplier capabilities in casting (Green sand moulding, Gravity Die casting, Pressure Die Casting, Low Pressure Die Casting) and precision machining.
• Lead continuous improvement projects throughout the casting and machining supply chain, focusing on best practices.
• Utilize data analytics to assess supplier performance and quality, identify key gaps, develop project plans and timelines, lead and implement processes aligned with defined objectives, and organize and present project updates to key stakeholders
• Profound Knowledge of metal casting methods, materials, and quality standards in greensand and shell moulding, preferably with hydraulic castings.
• Should have familiar with various grades of casting like grey iron, compacted graphite iron & SG iron
• Visit supplier site to witness casting & machining trials & report outcome to the SQA Manager & Global team.
• Conduct audits and capability assessments for supplier onboarding and qualification.

New Product Introduction (NPI)

• Lead DPAR (Design, Process and Application Review) for new components – Castings & machining (Green sand moulding, Gravity Die casting, Pressure Die Casting, Low Pressure Die Casting)
• Collaborate with suppliers on APQP i.e. conduct print reviews, co-ordinate with engineering for resolution of supplier technical queries.
• Collaborate with suppliers on PPAP i.e. review Process flow charts, PFMEA, Control plan, ISIR, Material test reports.
• Drive safe launch plans and heightened controls for critical components.
• Coordinate with design and sourcing teams for localization and industrialization of new parts.

Technical & Process Support

• Provide guidance on foundry tooling design, casting simulation, cutting tool selection, machining fixture design, and process optimization.
• Support implementation of CMMs, vision systems, and automated inspection tools.
• Conduct onsite process audits as per control plan and PFMEA validations to ensure robust process adherence & control.

Rework Management

• Coordinate with suppliers and third-party agencies for rework activities.
• Prepare and approve rework SOPs and validate reworked parts with plant quality teams.

Continuous Improvement

• Lead supplier Kaizen events and capability enhancement programs.
• Drive cost, quality, and delivery improvements using Lean and Six Sigma tools.
• Support make-buy analysis and tooling/programming optimization.

Qualifications & Skills:

• BE/Diploma in Mechanical or Production Engineering.
• Minimum 10 years of experience in supplier quality and development, with strong exposure to - Green sand moulding, Gravity Die casting, Pressure Die Casting, Low Pressure Die Casting and machining processes.
• Hands-on experience with APQP, PPAP, FMEA, SPC, MSA, ISO 9001, and IATF 16949.
• Proficiency in GD&T, CMM inspection, and machining tolerances.
• Strong analytical, problem-solving, and cross-functional collaboration skills.
• Six Sigma Green Belt certification preferred.
• Willingness to travel to supplier locations for audits and development activities.