About the Role
The QA & QMS Engineer will be responsible for establishing, implementing, and maintaining a Quality Management System aligned with IATF 16949 standards, while ensuring consistent product quality across foundry and machining operations.
The role requires strong expertise in quality system development, casting defect analysis, machining inspection, and customer complaint handling, ensuring compliance with automotive OEM quality requirements.
Key Responsibilities
1. Quality Management System (QMS)
* Establish and maintain IATF 16949 aligned Quality Management System.
* Develop and maintain quality documentation including:
Process Flow Diagrams
PFMEA
Control Plans
SOPs / Work Instructions
Inspection Standards
* Implement document control and revision management systems.
* Maintain product traceability and batch control systems.
* Ensure gauge calibration and measurement system control.
* Conduct internal audits and process audits.
* Implement Layered Process Audits (LPA) across shop-floor operations.
* Ensure closure of Non-Conformities (NCRs) identified during audits.
* Prepare reports and documentation for Management Review Meetings (MRM).
2. Automotive Quality Systems (APQP / PPAP)
* Support APQP planning for new product programs.
* Prepare and maintain PPAP documentation, including:
PFMEA
Control Plans
Process Flow Diagrams
MSA Studies
SPC Data
Process Capability Studies (Cp/Cpk)
* Maintain customer PPAP approval records.
* Ensure compliance with OEM customer-specific requirements.
3. Foundry Quality Assurance (Casting)
* Monitor melt chemistry using spectrometer.
* Control raw material and charge mix traceability.
* Monitor sand parameters including:
AFS
Permeability
Moisture
Green Strength
* Maintain metallurgical testing records.
* Identify and analyze casting defects such as:
Shrinkage cavities
Gas porosity / blowholes
Sand inclusions
Cold shuts
Misruns
Hot tears
Slag inclusions
* Conduct root cause analysis and implement corrective actions.
4. Machining Quality Assurance
* Conduct dimensional inspection using CMM and precision gauges.
* Interpret engineering drawings and GD&T requirements.
* Define in-process inspection checkpoints.
* Implement SPC monitoring for critical dimensions.
* Monitor process capability and dimensional stability.
5. Customer Quality & Complaint Handling
* Investigate customer complaints and field issues.
* Implement immediate containment actions.
* Conduct root cause analysis using:
7QC Tools
Why-Why Analysis
Six Sigma Methodology
* Prepare and submit 8D reports to customers.
* Track Customer PPM and rejection trends.
6. Continuous Quality Improvement
* Monitor internal rejection and defect trends.
* Lead root cause analysis for major quality issues.
* Implement improvement initiatives using Six Sigma methodology.
* Monitor process capability (Cp/Cpk).
* Support FIFO and traceability implementation.
Key Performance Indicators (KPIs)
* Reduction in internal rejection (foundry & machining)
* Customer complaint closure time
* PPAP approval readiness
* QMS documentation readiness for audits
* Improvement in process capability
