Quality / Manufacturing Engineer — Castings

 

Serve as SQA’s commodity subject matter expert and assessment lead for a two-day, on-site readiness assessment of a first-time casting supplier. Working alongside an SQA Technical Lead for FAI and metrology, you will lead the Requirements Consumption Review, the failure-mechanism-driven commodity assessment, and the PPAP readiness review, and author the final report identifying gaps and their risk to specification and on-time delivery.

 

▪    Lead the on-site assessment as the castings commodity SME, including the opening meeting, daily out-briefs, and closing meeting with the supplier and client.
▪    Facilitate the Requirements Consumption Review (RCR) with the supplier’s cross-functional team and client (virtual), covering contract review, product definition, build plan, inspection and test, CAPA, general workmanship, and tooling / property management.
▪    Walk the casting process flow step by step — pattern and gating, melt and chemistry, pouring and solidification, heat treatment, cleaning and finishing, weld repair, NDT, and shipment — identifying credible failure mechanisms and evaluating the prevention and detection controls in place (reverse-PFMEA approach).
▪    Evaluate QMS effectiveness as applied to the part, including MRB, nonconformance handling, corrective action, traceability, and continuous improvement.
▪    Where PPAP is required, assess the supplier’s readiness to execute a compliant PPAP: APQP planning, process flow, PFMEA, control plan, capability studies, and submission process.
▪    Evaluate schedule feasibility and capacity against quoted lead times and identify risks to on-time delivery.
▪    Consolidate findings with the Technical Lead into a gap register, rating each gap by risk and state of control, and recommend actions for the client and supplier.
▪    Escalate any observation posing an immediate risk to conformance or schedule to SQA within one business day.
▪    Author the Supplier Readiness Assessment Report for SQA technical review within the required timeline and support the client readout.

▪    Bachelor’s degree in mechanical, metallurgical / materials, manufacturing, or industrial engineering, or an equivalent combination of education and at least 10 years of directly related experience.
▪    Minimum 7 years of hands-on quality or manufacturing engineering experience in metal casting operations (sand, investment, or permanent mold).
▪    Demonstrated working knowledge of casting failure mechanisms (porosity, shrinkage, inclusions, hot tears, cold shuts, misruns, dimensional distortion) and the process controls that prevent them.
▪    Working knowledge of casting NDT methods (RT, PT, MT) and of chemical and mechanical property verification, including test bars and coupons.
▪    Hands-on experience developing or reviewing PFMEAs and control plans, and executing or reviewing PPAP / APQP per AIAG requirements.
▪    Prior experience leading supplier audits or assessments, with lead auditor training or certification to ISO 9001 or AS9100.
▪    Ability to read and interpret engineering drawings and GD&T per ASME Y14.5.
▪    Strong technical writing skills; able to produce clear, evidence-based reports on deadline.
▪    Able to travel to and work on site at the supplier facility for the full two-day assessment, including shop-floor access with required PPE.