Dec 2023 – Present · 2 yrs 5 mos · Jaipur, Rajasthan, India · On-site

• In my role as a Senior Quality Engineer at a green sand foundry, I am responsible for implementing and maintaining robust Quality Management Systems in compliance with ISO 9001 and IATF 16949, specifically tailored to the production of automotive cast iron components such as Hubs, carriages,
• brackets, housings, and suspension parts.
• My key responsibilities include:
• Quality Planning & System Implementation:
• Leading the execution of APQP, PPAP, and Control Plan activities for new product development and serial production.
• Process & Quality Control:
• Monitoring core making, moulding, melting, and pouring processes, ensuring process capability (Cp, Cpk), SPC, and in-process quality checks are in place to meet dimensional and metallurgical standards.
• Defect Prevention & Analysis:
• Conducting detailed analysis of casting defects (e.g., blowholes, shrinkage, porosity) using 8D, 5Why, and Root Cause Analysis (RCA) methods, and implementing effective Corrective & Preventive Actions (CAPA).
• Audit Management:
• Coordinating internal audits, supplier audits, and preparing for customer and third-party audits with a focus on zero non-conformances.
• Documentation & Compliance:
• Maintaining quality documentation including FMEA, MSA, work instructions, and inspection reports, ensuring full traceability and process adherence.
• Customer Interaction:
• Handling quality complaints, initiating customer concern analysis, and driving quick resolution to meet OEM and Tier-1 quality expectations.
• With a focus on defect-free production, cost reduction, and customer satisfaction, I continuously drive quality improvements across the foundry to meet the demanding standards of the automotive industry.

Feb 2022 – Nov 2023 · 1 yr 9 mos · Bharuch, Gujarat, India · On-site

• As a Metallurgical Lab Engineer in a green sand foundry, I am responsible for ensuring the metallurgical integrity and compliance of castings used in automotive and manifold applications, in alignment with IATF 16949 and ISO 9001 quality standards.
• My role supports the foundry’s core objective of delivering defect-free, high-performance cast iron components by combining hands-on laboratory testing with strong process knowledge and data-driven quality control.
• 🔩 Key Responsibilities:
• Metallurgical Testing & Validation
• Conducting microstructure & macrostructure analysis, hardness testing, tensile strength, impact testing, and chemical composition analysis using spectrometer and wet chemistry methods.
• Monitoring nodularity, graphite type, and matrix structure in ductile and grey cast iron components per ASTM/ISO standards.
• Sand Testing & Control
• Performing green sand and core sand testing (moisture, permeability, compactability, GCS, AFS grain fineness) to ensure mould quality consistency.
• Supporting melt quality control, including inoculation, temperature monitoring, and ladle metallurgy practices.
• Quality Management System (QMS) Compliance
• Maintaining test records, material traceability, and lab documentation as per IATF 16949 / ISO 9001 requirements.
• Participating in internal audits, customer PPAP documentation, and material certification issuance.
• Defect Analysis & Improvement Support
• Assisting quality and production teams in analyzing metallurgical root causes of defects like shrinkage, inclusions, and microstructural anomalies
• Ensuring all lab procedures and results align with automotive quality requirements, OEM specs, and material performance benchmarks for components under thermal and mechanical stress (e.g., manifolds, brackets, engine parts).
• This role bridges metallurgy, quality control, and automotive product reliability, ensuring every casting meets the mechanical and structural integrity demanded by global OEMs and Tier-1 suppliers.

Jun 2020 – Jan 2022 · 1 yr 7 mos · Bhiwadi Alwar · On-site

• This role provides foundational experience in metal casting quality assurance, helping ensure that critical automotive and manifold components meet performance and durability standards through proper testing and process discipline.