Senior Engineer - PDI Quality, HPDC Quality

JOB DESCRIPTIONJob Title:Sr. EngineerReporting to:Asst. Manager / ManagerDepartment:Quality Assurance
Paint Shop & PDINo. positions:01Location:Bangalore Plant Job Purpose:The Sr. Engineer Paint Shop & PDI is responsible for ensuring the quality of painted and finished aluminium die-cast components, conducting PDI inspection, controlling non-conformities, coordinating customer inspections and requirements, and supporting timely dispatch of conforming products.
Principal Accountabilities:

Paint Shop Quality Control

• Monitor paint shop processes such as surface preparation, pretreatment, coating/painting, curing and final visual appearance as applicable.
• Ensure compliance with approved work instructions, control plan, inspection standards and customer specifications.
• Conduct in-process and final inspections for colour, shade, gloss, coating coverage, adhesion, scratches, dents, peel-off, contamination, pin holes and other paint defects.
• Verify defined process parameters such as paint mixing ratio, viscosity, booth conditions, curing temperature/time and other controls.
• Identify abnormalities and coordinate immediate containment and corrective action with Production and Paint Shop teams.

PDI Inspection & Product Release

• Plan and perform PDI inspection for finished aluminium die-cast components before dispatch.
• Verify dimensional, visual, functional, marking, packing and customer-specific requirements as defined in the Control Plan / PDI checklist.
• Ensure only OK and approved parts are released for dispatch and maintain proper inspection status identification.
• Verify traceability, batch/lot details, date code, quantity, inspection records and packing condition before dispatch.
• Maintain PDI records, inspection reports and product release documentation with proper traceability.

Customer Handling & Coordination

• Coordinate with customers for PDI inspection, customer visits, sample verification and quality-related requirements.
• Attend customer complaints, line issues and quality concerns and provide timely containment and action updates.
• Support preparation of 8D / CAPA / corrective action reports using 7QC tools and structured root cause analysis.
• Coordinate customer sample submission, deviation approvals, inspection reports and other quality documents.
• Communicate customer requirements internally and ensure effective implementation at Paint Shop, PDI and dispatch stages.

Documentation & Reporting

• Maintain inspection records, PDI check sheets, paint inspection reports, rejection records and customer communication records.
• Ensure latest drawings, specifications, Control Plans, SOPs, work instructions and inspection standards are available at the workplace.
• Maintain ECN / change records and ensure changes affecting paint or PDI inspection are implemented after approval.
• Prepare daily / weekly quality reports covering rejection, rework, PDI status, customer issues and action closure.

Problem Solving & Continuous Improvement

• Conduct root cause analysis for paint defects, PDI rejections and customer complaints and implement effective corrective and preventive actions.
• Participate in Kaizen, Poka-Yoke, defect reduction and process improvement activities.
• Monitor quality trends and initiate actions to reduce internal rejection, customer rejection, rework and sorting.
• Conduct process / layered audits and verify effectiveness of corrective actions.

Team Coordination & Compliance

• Provide training and awareness to Paint Shop, PDI and inspection personnel on quality standards and customer requirements.
• Attend DWM and communicate quality issues, containment and corrective action status.
• Coordinate with Paint Shop, PPC, Dispatch and Customer Quality teams.

Knowledge & Skills needed to deliver on the accountabilities:
Technical Skills

• Paint Shop Quality Control
• PDI / Final Inspection
• Casting & Surface Defects
• Drawing & Specification Reading
• 7QC Tools / 8D / CAPA
• Basic SPC / MSA / Problem Solving
• Customer specific requirements

Soft Skills

• Communication Skill
• Time Management
• Report Writing
• Customer Coordination
• Presentation Skill

Behavioral Skills

• Problem Solving
• Team Work
• Decision Making
• Ownership & Accountability

Formal Education Requirements, as applicable & Relevant Experience:

• Bachelor's Diploma / B.Tech / B.E. Mechanical / Production / Metallurgy or relevant engineering discipline.
• Minimum 68 years relevant experience in aluminium die casting / automotive manufacturing quality.
• Experience in Paint Shop quality, PDI / final inspection and customer handling preferred.
• Knowledge of Control Plan, PFMEA, PPAP, 8D and customer specific requirements preferred.

Organizational Relationships HierarchyAsst. Manager / ManagerSr. Engineer Paint Shop & PDIPDI / Line InspectorsInspection / Paint Shop OperatorsExternal Stakeholder Interactions, if any: Internal & External Customer, Customer Quality / PDI Team, Suppliers, Paint / Chemical Suppliers and Service Providers.Prepared by Date: Last updated by: Date:
Sr. Engineer Paint Shop, PDI & Customer Handling