Quality Assurance Executive

Contact [hidden] JOB ROLE •   Own the quality-control system of the Mechanical Division covering incoming material, in-house fabrication, outsourced job-work and finished products, so that every critical part moves from drawing to a recorded, traceable quality approval. •   Replace judgement-based visual checks with measurable acceptance criteria, standardised inspection methods, calibrated instruments and dedicated gauges/fixtures, and progressively shift the division from detecting defects to preventing them. 2.0 KEY RESPONSIBILITIES •    Incoming inspection: Inspect raw material, laser-cut, fabricated and machined parts, hardware, fasteners, gaskets and bought-out items against PO, BOM, drawing and Material Test Certificate; record results on the MAF and tag, segregate and control non-conforming material. •    Acceptance standards: Prepare and maintain part-wise Material Acceptance Formats (MAF) stating drawing no./rev., material grade, critical dimensions with tolerances, finish, coating and welding requirements, sampling quantity, instrument to be used and accept/reject criteria. •    Inspection documentation: Develop in-process/stage checklists, First Article Inspection formats, ITPs/QAPs, final inspection reports and product check sheets; for every new product, fix the inspection method with Design and Production before regular production starts. •    Drawing compliance: Verify parts against the latest approved drawing revision, identify critical dimensions and GD&T features needing controlled inspection, and refer unclear tolerances to Mechanical Design. •    In-process inspection: Carry out stage-wise checks at laser cutting, drilling/tapping, welding, grinding, fabrication, fitting and assembly; clear critical dimensions before a part moves to the next stage. •    Outsourced processes: Inspect bending and powder-coating job-work on receipt for dimensions, DFT, adhesion, shade and finish before it is accepted into production. •    Welding and coating: Check joint preparation, weld size, distortion, porosity, undercut, cracks and spatter; for coatings check DFT, adhesion, uniformity and corrosion, using measured values in place of visual judgement wherever possible. •    Final inspection and release: Verify overall dimensions, GA drawing compliance, door/hinge/lock/handle operation, gasketing, fastener torque, clearances, nameplates and workmanship, and issue quality clearance; no product is dispatched without it. •    Gauges and fixtures: Select the right instrument for each check; for repetitive parts, develop GO/NO-GO gauges, hole-position/PCD templates and profile/checking fixtures with Design and Production, made in-house by laser cutting or machining, or 3D printed where non-critical. •    Inspection equipment: Periodically assess the need for advanced equipment (profile projector, vision system, CMM, roughness/hardness testers), justified on accuracy, rejection, volume and return on investment. •    Calibration: Maintain the master list of measuring instruments with unique ID, calibration frequency, records and traceability; withdraw and quarantine damaged or out-of-calibration instruments. •    Non-conformance and CAPA: Raise NCs on the company NC form for incoming, in-process, vendor and final failures; carry out root-cause analysis (5-Why, Fishbone, Pareto), implement CAPA, verify its effectiveness and track repeat defects. •    Vendor quality: Define vendor-specific acceptance criteria, monitor vendor rejection, inspect at vendor premises where required, share NCs and support Purchase in vendor evaluation. •    Improvement and records: Introduce poka-yoke, digital instruments, QR/barcode traceability and inspection records in ERPNext; keep records audit-ready as per ISO 9001:2015. •   Keep the assigned workstation/desk arranged, and keep the tools, equipment and computers used clean and in good condition. •   Make every reasonable effort to complete assigned work using available information, approved resources and one’s own knowledge and problem-solving ability; seek guidance from the senior only after checking the options, explaining the difficulty and the steps already taken. 3.0 AUTHORITY •   Reject or hold incoming material and job-work that does not meet the MAF or drawing. •   Stop a manufacturing process where a critical quality deviation exists, until it is corrected. •   Hold defective finished products and withhold quality clearance for dispatch. •   Raise NCs against internal departments and suppliers and require corrective action within an agreed time. •   Issue inspection formats and acceptance standards for the Mechanical Division after review by the Quality Head. •   Withdraw from use any instrument that is damaged or beyond calibration validity. •   Recommend new instruments, gauges, fixtures and inspection machinery to the Management. 4.0 SKILLS AND COMPETENCIES •   Reading of fabrication, machining and assembly drawings, including GD&T, tolerances and BOMs. •   Hands-on use of vernier, micrometer, height/depth/bore gauges, dial indicators, thread/radius/feeler gauges, DFT meter and torque wrench. •   Working knowledge of sheet-metal, laser cutting, bending, welding, machining and powder-coating processes and their typical defects. •   Sampling inspection, calibration, RCA/CAPA tools and ISO 9001:2015 documentation. •   Ability to conceive simple gauges and fixtures; AutoCAD, SolidWorks or Creo is an advantage. •   Working proficiency in MS Excel/Word and ERP data entry (ERPNext preferred). •   Clear communication with Production and vendors, and firmness in holding non-conforming product. 5.0 QUALIFICATION AND EXPERIENCE •    Qualification: Diploma / B.E. / B.Tech in Mechanical, Production or Manufacturing Engineering. •    Experience: Any one of the following: –  4–8 years in mechanical quality/inspection in sheet-metal fabrication, industrial enclosures, control panels or transformer accessories; OR –  2–4 years in quality/inspection within the transformer-accessories or electrical-panel industry, with hands-on inspection and documentation exposure; OR –  6 years or more in mechanical quality/inspection in any other engineering manufacturing field (machining, automotive, general fabrication), with the aptitude to be trained on transformer-accessory products. 6.0 KEY PERFORMANCE INDICATORS (KPIs) •   Customer complaints and customer rejections attributable to mechanical quality. •   Internal rejection and rework percentage; First-Pass Yield. •   Incoming material and vendor rejection rate; NC closure time and repeat-defect percentage. •   Calibration compliance – all instruments in use within calibration validity. •   Inspection record completeness; parts covered by measurable MAF. •   Gauges and fixtures introduced, and the resulting reduction in inspection time and errors. •   Trend in cost of poor quality (scrap, rework, replacement).