✅ Quality Assurance & Control
🔧 Quality Management System
- Lead the implementation, maintenance, and continuous improvement of QMS as per ISO 9001 or equivalent.
- Establish and regularly update SOPs, inspection protocols, and quality control plans across all foundry operations.
- Plan and lead internal audits, customer audits, and third-party certification audits.
📊 Inspection & Testing Oversight
- Oversee raw material, in-process, and final product inspections.
- Approve and review inspection reports, test certificates, and dimensional reports.
- Ensure availability and calibration of all inspection and testing equipment (e.g., hardness testers, gauges, CMM, NDT tools).
🧾 Customer Quality Assurance
- Act as the primary liaison with customers for quality complaints, audits, and quality documentation.
- Drive root cause analysis and close out of customer complaints and non-conformities (NCRs).
- Lead First Article Inspections (FAI), PPAP submissions, and pre-dispatch inspections.
🔍 Defect & Scrap Analysis
- Analyze casting defects and rejections and lead cross-functional teams for corrective actions.
- Maintain casting defect Pareto charts and drive actions to reduce internal rejection and customer return rates.
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🛡️ Health, Safety & Environment (HSE)
🚧 Occupational Safety Management
- Develop, implement, and enforce workplace safety policies and procedures based on OSHA/NEBOSH or equivalent standards.
- Conduct regular safety audits, risk assessments, and job safety analysis (JSA).
- Ensure availability and correct usage of PPE and conduct toolbox talks.
🌱 Environmental Compliance
- Monitor air emissions, noise, and waste disposal as per local environmental laws.
- Coordinate with external agencies for environmental impact assessments (EIA) or compliance checks.
- Promote resource conservation (e.g., water, energy, raw materials).
📋 Incident Management & Reporting
- Investigate all incidents, near misses, and injuries, and document root cause findings and preventive measures.
- Maintain updated safety logs, MSDS, and emergency response procedures.
- Report to management and regulatory bodies as required.
👨🏫 HSE Training & Awareness
- Conduct induction training for new hires and routine HSE training for staff and contractors.
- Lead fire drills, emergency preparedness programs, and safety campaigns.
- Promote a safety-first culture throughout the organization.
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🤝 Cross-Functional Collaboration
- Coordinate with Production, Maintenance, Planning, and Supply Chain teams to ensure quality and safety at every stage.
- Work with HR to ensure training compliance and worker health monitoring.
- Participate in project planning, new process development, and investment proposals from the QA/HSE perspective.
📌 Qualifications & Requirements
- Bachelor’s degree in mechanical/metallurgical/industrial engineering or related field; Safety Certifications (NEBOSH, IOSH, OSHA) preferred.
- 8+ years of combined QA/QC and HSE experience, with at least 3 years in a managerial role in a foundry or heavy manufacturing environment.
- Strong knowledge of casting processes (sand casting, shell mold, induction furnace) and quality tools (SPC, FMEA, CAPA, 8D).
- Familiarity with ISO 9001, ISO 14001, and ISO 45001 systems.
- Hands-on experience in managing audits, safety inspections, and defect analysis.
- Excellent leadership, problem-solving, and cross-functional coordination skills.
- Proficiency in MS Office, ERP systems, and quality data analysis tools.
