Manager (Quality Control & Assurance)

Job Description

Position: Manager – Quality Control & Assurance

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

Reports To: Head – Quality / Plant Head / General Manager

Role Summary:

The Manager – Quality Control & Assurance is responsible for leading and managing the entire quality function, covering incoming, in-process, and final inspection of forged products. The role ensures metallurgical and dimensional compliance of forgings with customer specifications, standards, and heavy-duty application requirements. The position involves setting quality policies, establishing robust inspection systems, managing customer interactions, driving supplier quality improvements, and ensuring certification/regulatory compliance. The Manager will also mentor and guide quality teams while promoting a culture of zero defects, continuous improvement, and customer satisfaction.

Key Responsibilities:

1. Quality Strategy & Policy

• Define and implement Quality Control & Assurance policies in alignment with company objectives.
• Establish QMS frameworks (ISO 9001, IATF 16949, API, ASME, customer-specific standards).
• Ensure compliance with statutory, regulatory, and heavy-duty industry quality requirements.

2. Quality Control Operations

• Lead incoming, in-process, and final inspection of forged components.
• Ensure metallurgical integrity through microstructure analysis, hardness, impact, tensile, and NDT (UT, MPI, DPI, Radiography).
• Monitor calibration of measuring instruments, gauges, and testing equipment.
• Implement statistical process control (SPC) and inspection systems to detect variations.

3. Quality Assurance & Documentation

• Oversee APQP, PPAP, FMEA, MSA, Control Plans, and process validation.
• Approve inspection reports, test certificates, and final product release documents.
• Maintain robust documentation for audits, customer approvals, and compliance requirements.

4. Customer Focus & Interaction

• Act as the primary contact for customer quality issues, audits, and approvals.
• Handle customer complaints, lead root cause analysis, and ensure timely corrective actions.
• Drive customer satisfaction through reliable product quality and proactive communication.

5. Supplier Quality & Collaboration

• Collaborate with Supplier Quality team to ensure defect-free raw materials and sub-contracted processes.
• Support supplier audits and qualification for forging, machining, and heat treatment vendors.
• Drive vendor development and supplier quality improvement initiatives.

6. Team Leadership & Development

• Lead and mentor a team of engineers, inspectors, and lab technicians.
• Build competency in metallurgical testing, NDT, and modern quality tools.
• Foster a quality culture across departments through training and awareness programs.

7. Continuous Improvement & Cost of Quality

• Lead root cause analysis (RCA), CAPA, and 8D problem-solving methodologies.
• Drive Lean Six Sigma and process capability improvements (Cp, Cpk).
• Reduce Cost of Poor Quality (COPQ), scrap, and rework.
• Initiate kaizen, mistake-proofing (poka-yoke), and defect-prevention strategies.

8. Audits & Certifications

• Plan and manage internal and external audits (ISO, IATF, API, customer audits).
• Ensure closure of audit non-conformances within committed timelines.
• Maintain certification compliance and continuous readiness for customer audits.

Skills & Competencies Required:

Technical Skills

• In-depth knowledge of forging processes, metallurgy, and heavy-duty application standards.
• Strong expertise in NDT, metallurgical testing, heat treatment, and dimensional inspection.
• Proficiency in quality tools: APQP, PPAP, FMEA, MSA, SPC, 8D, RCA.
• Hands-on experience in QMS implementation and certification audits.
• Exposure to customer requirements in heavy-duty sectors (construction, oil & gas, railways).

Soft Skills

• Strong leadership and people management skills.
• Excellent analytical and problem-solving ability.
• Effective communication and customer-handling skills.
• Negotiation and influencing capability with suppliers and internal stakeholders.
• Strategic mindset with focus on continuous improvement.

Qualification & Experience

• Education: B.E./B.Tech in Metallurgy / Mechanical Engineering.
• Experience: 10–15 years in Quality Control & Assurance within Forging/Heavy Engineering industry.
• Certifications: Lead Auditor (ISO/IATF), Six Sigma Green/Black Belt, NDT Level II/III desirable.