Description

Department: Quality Assurance
Reports To: VP of Quality
Job Type: Full-Time

Direct Reports:

• Casting quality technician and testing associate
• Quality OSP and shipping manager
• Casting Quality – Metallurgical Testing and Heat Treat Process Owner
• Quality Hourly Employees (6)

Job Summary:

We are seeking a highly skilled and detail-oriented Sand-Casting and Machining Center Quality Manager to oversee and manage the quality assurance functions within our foundry operations. The ideal candidate will have extensive experience in sand casting processes, quality control systems, and industry standards. This role ensures all castings meet or exceed customer requirements, internal quality standards, and regulatory compliance.

Key Responsibilities:

Quality System Management:

• Lead the development, implementation, and continuous improvement of the organization's quality management system (QMS) in compliance with ISO 9001 or equivalent standards.
• Maintain and update process and product documentation, control plans, internal audit, corrective action, configuration management and standard operating procedures.
• Conduct internal and supplier audits as necessary.

Process & Product Quality:

• Monitor critical stages of the sand-casting process (mold and core preparation, pouring, cooling, shakeout, finishing) to ensure quality standards are met.
• Oversee testing procedures including dimensional inspections, surface defect analysis, non-destructive testing (NDT), functional and metallurgical evaluations.
• Create production packets and in process conformance data.

Defect Analysis & Problem Solving:

• Lead root cause corrective action (RCCA) for casting defects such as porosity, inclusions, shrinkage, dimensional and cosmetic issues / surface roughness.
• Implement corrective and preventive actions (CAPA) using tools like 5-Why, Fishbone, and FMEA as required.

Team Leadership:

• Supervise quality inspectors and lab technicians; provide training, performance evaluations, and mentoring.
• Foster a quality-first culture across all production teams with a keen customer focus.

Customer & Compliance Management:

• Interface with customers on quality issues, audits, and corrective actions.
• Customer quality point of contact for field topics and on-site assessments.
• Investigate field issues and deviations with intent on corrective and preventive actions.
• Ensure compliance with industry regulations, customer requirements, and internal standards.

Continuous Improvement:

• Identify and implement process improvements using basic quality tools, lean manufacturing and Six Sigma principles.
• Strong proficiency in data capture and analytics.
• Develop and track key performance indicators (KPIs) such as scrap rates, rework, warranty costs and first-pass yield. Prepare summarize and communicate periodic corporate metrics.

Qualifications:

Education:

• Bachelor's degree in Metallurgy, Materials Science, Mechanical Engineering, or related field (required).
• Quality certifications such as CQE, Six Sigma, or ISO Lead Auditor are a plus.

Experience:

• Minimum 7 years of experience in a foundry or metal casting environment, with at least 2 years in a quality management or prime designee role. Primarily bronze aluminum and stainless steel.
• Hands-on experience with sand casting processes (green sand, resin sand, shell mold, etc.).
• Strong familiarity with conventional machining processes including: manual CNC lathes, manual and CNC milling (vertical and horizontal) including “tombstone”-style arrangements.
• Practitioner of electronic spectrometry for material composition and material tensile and mechanical testing.

Required Skills:

• Strong knowledge of casting processes, defects and metallurgical principles.
• Proficient in quality tools (SPC, CMM, NDT, MSA, PPAP, lean, etc.).
• Quality metrics formulation and forecasting.
• Budget development and management.
• Excellent leadership, communication, and analytical skills.
• Ability to read technical drawings, GD&T, MIL-spec, and material specifications.
• Project oversight and planning.

Preferred skills

• Strong familiarity and / or practitioner of Navy NAVSEA, electric boat (EB), Level 1 specifications and certification.
• 3D printed core processing and optimization
• Familiarity with hydro testing for leakage

Working Conditions:

• Primarily in a manufacturing/foundry environment with exposure to heat, noise, and dust.
• Must be able to wear PPE and navigate the shop floor regularly.
• Occasional travel may be required for customer visits or supplier audits.

Why Join Us?

• Competitive salary and benefits
• Career growth opportunities
• A team-oriented work environment
• Commitment to innovation and quality