GM - Plant Quality Assurance - Halol, Gujrat

Key Purpose of the Job (Position Summary)

The position is responsible to ensure 100% quality of product as per the plant process standard, thereby eliminating the waste, defectives & rework and rejections. Addressing and resolving in process quality issues raised through customer complaints and improvement of in process quality. The role holder is also responsible to implement quality initiatives, improvement activities and special projects at the plants in alignment to quality strategy and guidelines.

KEYPERFORMANCE AREAS

• Adherence to the plan for sampling, inspection and testing
• Ensure reduction in rejection
• Ensure timely resolution of customer complaints
• Ensure reduction of claims
• Ensure timely and effective process and product audit
• Ensure implementation of improvement projects

KEY ACTIVITIES  & RESPONSIBILITIES

Strategy & Planning:

• Implement strategies for the plant quality in consultation with Quality head
• Initiate, design & implement quality processes & systems in a structured manner.
• Carry out planning for department on line with functions objectives.
• Keep abreast with the national & international quality standards.
• Identify, plan and initiate investment requirements e.g., quality tools, testing facility, systems etc.
• Install effective processes & standardize for defect free output from production.

Plant Quality Assurance

• Develop, implement and manage quality control / quality assurance activities in the plant to maximize product quality and customer satisfaction through effective preventive controls
• Monitor quality practices and procedures being implemented to ensure conformity to quality assurance and safety standards.
• Review the quality standards regularly based on customer requirements and feedback.
• Develop, maintain and review quality control charts & database.
• Create documents and implement inspection criteria and procedures.
• Train sectional heads in quality systems, tools and techniques to ensure that quality becomes way of working
• Implement projects to address quality gaps / defects identified and ensure standardization of resolution in processes, as applicable
• Develop new process / testing techniques and introduction of new methods to ensure quality and cost control

Plant Quality Management

• Drive the interim and final product audit and testing process
• Work closely with section supervisors to plan, schedule and implement QA related activities.
• Participate in plant level discussion to draw up action plans to arrest quality rejection occurrences
• Conduct Why-Why Analysis and create /update control plans regularly
• Conduct Root cause analysis and take corrective actions to avoid repeat of chronic errors
• Give recommendations to the Production and the R&D on specific quality parameters and non conformities to assist in development of new components, parts or products.
• Create and implement a system to ensure product quality traceability throughout the process flow
• Ensure Quality checks are conducted for all inward material/products in coordination with the Purchase team.
• Supervise in-process quality checks at every step of the process to ensure that the products are produced as per customer specified dimensions and standards.
• Inspect finished products to check if they meet the desired quality standards as specified by the customer.
• Participate in the new product development process by ensuring quality parameters are checked

Customer support

• Monitor and manage customer complaints and provide corrective action to avoid recurrences.
• Investigate the technical aspects of customer complaints and provide reports to Plant Head for remedial actions.
• Participate in quality related discussions with Customers and facilitate cascading of the concerns to line heads and other stakeholders in plant
• Support the Plant Head in discussions with the customers to resolve disputes with respect to customer rejections
• Address customer complaints leading to warranty claims due to gaps in production processes through study, in-depth analysis, process improvements, tools and other techniques
• Review warranty parts analysis and customer complaints and recommend suitable action

Raw material quality

• Monitor quality of all inward materials such as raw materials, indirect materials and report back to vendors in case of any quality issue.
• Resolve vendor quality and performance issues by participating in implementation of quality systems at Vendors
• Conduct sample checks across plants/ locations to assess equipment reliability and check accuracy of results
• Conduct quality audits and recommend corrective procedures
• Conduct review with supplier senior management to escalate and close ongoing issues in purchased parts, in consultation with the Plant Head.

Systems and Process

• Develop and maintain QA standards relating to processes and products
• Monitor QA systems and advise team on system performance publish statistics regarding performance against set goals
• Track the quality reports generated by the team to identify and track deviations
• Ensure adherence to Quality systems such as ISO 9001,OHSAS,etc
• Perform gap analysis between applicable and current ISO standards establish and implement a quality plan to bring the company into ISO compliance
• Support new product development and continuous improvement and by integrating quality control tools (e.g. Lean, Six Sigma, etc.) into processes

MIS and Reports

• Define standard guidelines and procedures for quality assurance reports and formats
• Ensure SAP is updated regularly and accurately by the team. 
• Prepare reports and make recommendations for improving overall quality and solving chronic problems
• Ensure compilation of information on - Quality status, Complaint sample results, Market sample results and major deviations. & Weekly report submission.
• Ensure documentation of various BIS and ISO 9000 related compliances.