The Quality Engineer supports and improves product, process, and system quality within an iron foundry environment. This role ensures that castings meet customer, regulatory, and industry requirements by leading quality systems activities, driving root cause analysis, and strengthening process capability. The Quality Engineer collaborates closely with operations, engineering, suppliers, and customers to maintain and elevate performance.
Quality Systems & Compliance
- Maintain and improve core quality system documents, including Control Plans, PFMEAs, and inspection methods.
- Author and update work instructions, test methods, standard operating procedures, and other quality documentation.
- Support Management of Change (MOC), including validation, qualification, and documentation.
Root Cause Analysis & Corrective Actions
- Lead structured problem solving using 8D, 5-Why, Fishbone, and similar methodologies.
- Own corrective action activities, ensuring timely closure, robust verification, and effectiveness checks.
Process Capability & Measurement
- Improve process capability by designing SPC strategies, control charts, and sampling plans.
- Conduct Measurement System Analysis (MSA) including Gage R&R, and optimize measurement techniques and equipment selection.
New Product Introduction & Customer Requirements
Lead or support PPAP activities, including PSW preparation, dimensional reports, capability studies, and validation documentation.
- Interpret customer specifications, inspection requirements, and special characteristics; ensure compliance across the manufacturing process.
Supplier Quality
- Support supplier quality activities, including incoming inspection plans, SCAR management, performance tracking, and supplier auditing.
- Partner with suppliers to resolve nonconformities and drive continuous improvement.
Data Analysis & Continuous Improvement
- Utilize data to identify trends, risks, and improvement opportunities in scrap, rework, dimensional variation, and customer returns.
- Participate in or lead Continuous Improvement projects focusing on quality, throughput, and cost reduction within the foundry process.
Required
- Bachelor's degree in Engineering, Materials Science, Manufacturing Technology, or related field; equivalent foundry/quality experience considered.
- Working knowledge of APQP, SPC, PFMEA, and Control Plans.
- Strong analytical capabilities and proficiency in Microsoft Office; familiarity with statistical software is a plus.
- Excellent communication, problem-solving, and cross-functional teamwork skills.
Preferred
- Experience with ISO 9001 or similar quality management systems.
- Experience with metals manufacturing, machining, or foundry processes.
- Knowledge of casting and machining processes (green sand, pattern design, metallurgy, CNC, etc.).
Physical and Work Environment Requirements
- Daily interaction with production areas including melting, molding, finishing, and machining.
- Ability to lift up to 25 lbs and use measurement instruments (calipers, micrometers, CMM interfaces, etc.) safely.
