Quality Assurance Engineer 1

Job Profile: Engineer Quality Assurance

Position Overview

The Quality Assurance (QA) Engineer will establish, implement, and maintain quality standards for the manufacturing of copper and copper alloy components (e.g., brass, bronze, cupronickel). This role ensures that all incoming raw materials, in-process production, and finished goods meet stringent metallurgical, dimensional, and customer-specific requirements. The ideal candidate possesses a strong background in metallurgy, destructive and non-destructive testing, and statistical process control (SPC).

Key Information

Department: Quality Assurance / Quality Control

Reports To: QA/QC Manager / Head of Quality

Employment Type: Full-time

Location: Sriperumbudur (Close to Chennai), Tamil Nadu

Key Responsibilities

Process & Product Quality Control

Monitor and audit the manufacturing processes of copper and copper alloy components, including casting, extrusion, drawing, forging, and machining.

Develop and implement Product Quality Plans (PQP), Control Plans, and Standard Operating Procedures (SOPs).

Ensure strict adherence to international standards such as ASTM, DIN, EN, and ISO.

Metallurgical & Physical Testing

Oversee metallurgical testing, including grain size analysis, microstructure evaluation, and hardness testing (Vickers/Brinell).

Supervise chemical composition analysis using Optical Emission Spectrometry (OES) or X-ray Fluorescence (XRF) to verify alloy grades.

Coordinate mechanical testing, including tensile strength, elongation, and electrical conductivity testing (IACS% verification).

Manage Non-Destructive Testing (NDT) processes, such as Eddy Current testing for surface defects and Ultrasonic testing for internal flaws.

Defect Analysis & Corrective Actions

Lead Root Cause Analysis (RCA) for internal rejections, customer complaints, and foundry defects (e.g., porosity, inclusions, scale).

Implement corrective and preventive actions (CAPA) using 8D, 5-Why, and Fishbone analysis methodologies.

Drive scrap reduction initiatives and analyze cost of poor quality (COPQ).

Supplier & Customer Quality Management

Audit and approve raw material suppliers, specifically focusing on copper cathode, scrap sorting, and master alloy inputs.

Manage customer quality audits and handle the compilation of Production Part Approval Process (PPAP) documentation.

Issue Material Test Certificates (MTC) in compliance with EN 10204 3.1/3.2.

Calibration & Compliance

Oversee the calibration schedule for all laboratory instruments, gauges, and melting furnace thermal probes.

Maintain and improve the ISO 9001:2015 Quality Management System (QMS).

Required Qualifications & Skills

Education

Bachelor’s Degree / Diploma in Metallurgical Engineering, Materials Science, or Mechanical Engineering.

Experience

3 to 6 years of experience in QA/QC roles within a non-ferrous metal manufacturing or foundry environment.

Hands-on experience with copper, brass, bronze, or copper-nickel alloys is highly preferred.

Technical Skills

Proficiency in reading engineering drawings, GD&T (Geometric Dimensioning and Tolerancing), and using precision measuring instruments (CMM, micrometers, verniers).

Strong understanding of statistical tools (SPC, MSA, FMEA, and PPAP).

Knowledge of standard heat treatment processes for copper alloys (annealing, stress relieving).

Certification in NDT Level II (Eddy Current / Ultrasonic Testing) is a strong advantage.

Soft Skills

Strong analytical and problem-solving mindset.

Excellent communication skills for cross-functional collaboration with production, tool room, and customers.

High attention to detail and a data-driven approach to quality.