Manager QA

Job Description:

Position: Manager – Quality Assurance (Steel Casting Foundry)

1. Educational Qualification

• B.E./B.Tech in Mechanical Engineering
• Preferred certifications:
• NDT Level II / III (UT, RT, MT, PT)
• Working knowledge of ISO 14001 and ISO 45001
• Hands-on experience in laser scanning and interpretation of inspection reports for decision-making

2. Experience

• 5–10 years in steel casting / foundry industry
• Minimum 5–7 years in a QA leadership role (this is slightly inconsistent with total experience—consider adjusting to 2–4 years leadership if hiring mid-level candidates)
• Hands-on experience in:
• Carbon steel, alloy steel, and stainless steel castings
• Export quality requirements (ASTM, DIN, BS, IS standards)

3. Key Responsibilities

Quality Management

• Develop, implement, and maintain QA/QC systems aligned with ISO 9001 and customer-specific requirements
• Ensure compliance with international standards (ASTM, ASME, EN)

Inspection & Testing

• Oversee and control:
• NDT: UT, RT, MPI, DPI
• Dimensional and visual inspection
• Review and approve inspection reports and final product release

Defect Analysis & Continuous Improvement

• Lead root cause analysis using:
• 8D methodology
• Practical Problem Solving (PPS)
• Fishbone (Ishikawa), Pareto analysis
• RCCA (Root Cause & Corrective Action)
• Drive initiatives to reduce rejection, rework, and improve first-pass yield

Customer & Audit Handling

• Manage customer complaints and ensure timely corrective actions
• Lead customer, third-party, and certification audits
• Act as the primary interface for customer quality approvals

Documentation & Traceability

• Ensure:
• Heat-wise traceability
• Inspection and calibration records
• Maintain full compliance with documentation and audit requirements

Team Leadership

• Lead and manage QA team including:
• Inspectors
• UT operators
• MPI operators
• Marking and scanning personnel
• Conduct training and skill development programs

4. Technical Skills

• Strong expertise in:
• Casting defects (shrinkage, porosity, inclusions, cracks)
• Engineering drawing interpretation
• GD&T (Geometric Dimensioning & Tolerancing)
• Proficient in:
• MS Office (Excel, Word, PowerPoint) for reporting and presentations
• Budgeting and cost tracking (quality-related costs)
• Familiarity with ERP/MIS systems for quality monitoring

5. Behavioural Competencies

• Strong analytical and problem-solving ability
• Leadership with quick and effective decision-making
• Excellent communication skills (especially customer-facing)
• High attention to detail and quality-focused mindset

6. KPIs (Key Performance Indicators)

• Customer rejection / return rate
• Customer complaint closure time
• Audit compliance score
• Reduction in Cost of Poor Quality (COPQ)

7. Preferred Industry Exposure

• Heavy engineering castings:
• Hydraulics
• Construction & earth-moving equipment
• Mining, railways, defense
• Experience in export-oriented foundries with stringent QA systems