Quality Manager (HPDC - High-Pressure Die Casting)

1. Quality Planning & Process Control

• Define and control Critical Quality Parameters (CQP) for HPDC (melt chemistry, melt temperature, die temperature, shot profile, vacuum levels, spray pattern, cooling circuits).
• Approve first off samples and ensure adherence to standard parameter windows.
• Validate process capability (Cp/Cpk), MSA (Gauge R&R), and CTQ controls.

2. Die Casting Defect Prevention

• Lead reduction of defects: porosity, cold shut, misrun, blister, shrinkage, cracks, soldering, inclusions, flash.
• Implement robust Poka Yoke controls (vacuum OK, die close confirmation, lube flow control, melt quality checks).
• Conduct DOE and root cause analysis for recurring issues.

3. Die, Tooling & Equipment Quality

• Approve new/modified dies using short shot study, fill balance, die thermal mapping, and vacuum acceptance checks.
• Collaborate with tooling/maintenance for die PM, die life tracking, refurbishment criteria, and tool condition audits.
• Monitor trim press, X ray, leak test, blasting, machining readiness for quality.

4. Melt Shop & Metallurgical Quality

• Ensure melt chemistry, degassing, hydrogen level control, dross removal, and alloy modification.
• Approve melt quality logs and metallurgical test reports.
• Control holding furnace parameters, ladle dosing accuracy, and transfer practices.

5. In Process & Final Inspection

• Establish inspection standards for:
• Porosity (X-ray criteria)
• Surface defects
• Dimensional CTQs
• Leak test, weight, burr/flash control

6. Customer Quality & APQP/PPAP

• Lead customer communication for casting quality issues, approvals, and part validations.
• Prepare and approve APQP documents: PFMEA, Control Plan, Flow Chart, MSA, capability studies.
• Submit and follow up on PPAP (Level 3 typically for die casting).
• Support customer audits, PPR, sample approvals, and Run@Rate.

7. Quality System Compliance

• Ensure compliance with IATF 16949, ISO 9001, and customer-specific requirements.
• Lead internal process audits, LPA, and product audits related to HPDC.
• Maintain documentation and ensure FMEA/Control Plan updates after any change.

8. Root Cause Analysis & CAPA

• Drive structured problem-solving (5 Why, Fishbone, 8D) for customer/internal rejections.
• Implement corrective/preventive actions with CFT (Tooling, Production, Maintenance).
• Track and close customer concerns within defined timelines.

9. Data Monitoring & KPI Management

• Internal PPM / Customer PPM
• Vacuum OK percentage

10. Training & Skill Development

• Train operators, inspectors, and engineers on:
• Casting defect identification

11. Cross Functional Coordination

• Work closely with Production, Tooling, Maintenance, NPD, SQA, Machining, and Customer Quality.
• Participate in daily shopfloor reviews, defect reduction meetings, and improvement projects.