Production & Quality Engineer

Job Description - Production & Quality Engineer (Spring Manufacturing)

*Position Title:* Production & Quality Engineer - Spring Manufacturing  

*Department:* Production & Quality  

*Reporting To:* Plant Head / Production Manager / Quality Manager  

1. Role Purpose  

To plan, set up, control, and continuously improve spring manufacturing processes (coiling, grinding, heat treatment, etc.) while ensuring that incoming material, in‑process production, and finished springs conform to customer specifications and quality system requirements. 

2. Key Responsibilities  

*A. Production Planning and Execution*  

- Prepare daily/shift-wise production plans based on customer orders and delivery commitments; allocate machines and manpower to meet production targets and optimize capacity utilization.

- Coordinate with Purchase, Sales, and Stores to ensure material availability and timely execution of orders.

*B. Process Setup, Qualification, and Control*  

- Set up and qualify coiling, forming, grinding, stress‑relieving, and shot peening processes as per engineering drawings, data sheets, and process documents. 

- Develop, optimize, and document machine parameters (feed, pitch, OD, cut length, temperature, time) to achieve required dimensions, loads, and cycle times.

- Conduct trial runs and first‑piece approvals in coordination with Quality before releasing products to mass production.

*C. In‑Process Monitoring and Troubleshooting*  

- Monitor output, yield, scrap, rework, downtime, and process stability; take corrective actions to resolve process and quality issues.

- Use basic data analysis and SPC (where applicable) to maintain process capability and reduce variation.

*D. Quality Inspection and Assurance*  

- Carry out incoming inspection of wire/strip and components for dimensional accuracy, certificates, and visual defects.

- Perform first‑piece, in‑process, and final inspections of springs (dimensional checks, load/deflection testing, hardness, visual inspection).

- Set up and operate inspection and testing equipment such as micrometers, vernier calipers, load testers, hardness testers, and ensure proper usage.

*E. Nonconformance, Root Cause Analysis, and CAPA*  

- Identify, segregate, and control nonconforming material; ensure proper disposition and traceability of nonconforming product.

- Lead or participate in root cause analysis for process and quality problems using 5 Why, Ishikawa, and other problem‑solving tools; implement and verify effectiveness of corrective and preventive actions.

*F. Quality System, Documentation, and Audits*  

- Prepare and maintain Control Plans, PFMEAs, work instructions, setup sheets, inspection standards, and process flow diagrams for spring products.

- Maintain inspection records, SPC charts, nonconformance reports, and quality metrics (PPM, scrap, rework, customer complaints).  

- Support internal and external audits (ISO 9001 / IATF 16949 or equivalent), customer audits, and PPAP / initial sample submissions by providing documentation and evidence.

*G. Calibration and Equipment Care*  

- Ensure measuring instruments and testing equipment are calibrated and maintained as per schedule; maintain records of calibration and equipment status.

- Promote proper storage, handling, and usage of gauges, instruments, and tooling.

*H. New Product Introduction and Continuous Improvement*  

- Support new product introduction (NPI) by developing and qualifying production and inspection processes for new spring designs.

- Participate in continuous improvement initiatives (Kaizen, 5S, Lean) to reduce scrap, improve productivity, and enhance quality performance.

*I. Safety, 5S, and Culture*  

- Ensure compliance with safety procedures for coilers, grinders, ovens, and material handling; report and help eliminate unsafe conditions.

- Maintain housekeeping and 5S standards in production and quality areas; promote a culture of safety, discipline, and quality. 

3. Qualifications  

- Diploma / Degree in Mechanical, Production, Industrial Engineering, or related discipline.  

- Fresher and 2-5 years experience in discrete manufacturing; experience in spring, wire‑form, or metal components manufacturing preferred.

- Ability to read and interpret engineering drawings, spring data sheets, and basic GD&T.

- Familiarity with quality tools (SPC, PFMEA, Control Plans, PPAP, Root Cause Analysis) and ISO/IATF quality systems.

4. Skills and Competencies  

- Strong analytical and troubleshooting skills for both process and quality issues.  

- Hands‑on, shop‑floor oriented approach; comfortable with machine adjustments and inspection work.

- High attention to detail and accuracy in measurement, documentation, and reporting. 

- Good communication and coordination skills for working with Production, Quality, Maintenance, Purchase, and customers.  

- Focus on safety, quality, delivery, and continuous improvement.