Senior Engineer

Position: Senior Engineer Supplier Quality Control

Industry: Metal Forging (serving Heavy Duty Industry Construction Equipment, Off-Highway Vehicles, Oil & Gas, Railways, Power Sector, Automotive, Boeing etc.)

Reports To: Quality Manager / Head Supplier Quality or Plant Head

Role Summary:

The Senior Engineer Supplier Quality Control (SQC) is responsible for ensuring that forged components, raw materials, and outsourced processes supplied to the organization meet stringent quality and reliability standards for heavy-duty applications. The role focuses on supplier audits, metallurgical quality assurance, process validation, corrective action management, and driving supplier development initiatives. This position acts as a critical link between suppliers, procurement, production, and customers to achieve zero-defect supplies and continuous improvement across the forging supply chain.

Key Responsibilities:

Supplier Quality Assurance

• Establish and implement supplier quality standards and inspection protocols specific to forging processes.
• Verify supplier compliance with customer specifications, drawings, and international standards (ASTM, ASME, SAE, API, ISO, IATF, etc.).
• Conduct supplier process audits covering forging, machining, heat treatment, NDT, and surface treatments.

Metallurgical & Process Control

• Review and approve supplier PPAP, process flow, and control plans for forged parts.
• Validate raw material test certificates (chemical, mechanical, ultrasonic, grain flow, impact testing).
• Ensure metallurgical integrity through microstructure evaluation, hardness checks, and NDT reports.

Incoming Quality & Inspection

• Develop and execute inspection plans for forged components and raw materials.
• Oversee dimensional checks, metallurgical tests, and defect detection at incoming stage.
• Coordinate with internal labs for metallurgical failure analysis of supplier parts.

Problem Solving & Corrective Action

• Investigate supplier-related non-conformances (e.g., cracks, laps, porosity, inclusions, hardness deviations).
• Drive root cause analysis (RCA) using structured tools (8D, 5-Why, Ishikawa).
• Implement corrective/preventive actions (CAPA) and ensure effectiveness at supplier end.

Supplier Performance & Development

• Monitor supplier KPIs PPM, rejection rates, on-time delivery, and quality performance.
• Maintain supplier scorecards and conduct quarterly reviews.
• Guide suppliers on quality improvement, lean manufacturing, and defect reduction.

Cross-functional Support & Customer Focus

• Support procurement in supplier selection and qualification.
• Collaborate with R&D/Design teams during New Product Development (NPD).
• Participate in customer audits, providing supplier quality documentation and evidence.

Continuous Improvement & Compliance

• Promote zero-defect mindset and process capability improvements (Cp, Cpk).
• Lead supplier-driven Six Sigma/Lean projects for defect and cost reduction.
• Ensure compliance with QMS, EHS, and regulatory requirements.

Required Skills & Competencies: -

Technical Skills:

• Strong knowledge of forging processes (closed die, open die, upset forging, ring rolling).
• Metallurgy expertise steel grades, alloy properties, heat treatment, grain flow.
• Proficiency in NDT methods – UT, MPI, DPI, Radiography.
• Knowledge of machining and surface finishing in forging industry.
• Familiarity with international heavy-duty industry standards (ASTM, SAE, API, ASME).
• Hands-on experience with quality tools – APQP, PPAP, FMEA, MSA, SPC, 8D, RCA.
• Experience in supplier audits and vendor quality assurance.

Soft Skills:

• Strong analytical and problem-solving ability.
• Effective communication and supplier relationship management.
• Ability to influence and negotiate with suppliers.
• Detail-oriented with focus on defect prevention.
• Cross-functional collaboration and customer handling.

Qualifications & Experience:

• Education: B.E./B.Tech in Metallurgy / Mechanical Engineering (preferred).
• Experience: 6–8 years in Supplier Quality Control / Forging Industry, with focus on heavy-duty applications.
• Certifications in Lead Auditor (ISO/IATF), Six Sigma Green Belt/Black Belt, NDT Level II/III will be an added advantage.