Deputy Manager/ Manager- Quality

1. Roles & Responsibilities

A. Quality Management System

1. Develop, implement, and maintain the Quality Management System as per ISO 9001 requirements.
2. Establish quality policies, objectives, procedures, SOPs, inspection standards, and quality plans.
3. Ensure compliance with applicable BIS/ISI standards, customer specifications, and statutory product requirements.
4. Plan and conduct internal audits, process audits, supplier audits, and customer audits.
5. Coordinate ISO certification, surveillance audits, and closure of audit non-conformities.
6. Conduct Management Review Meetings and monitor quality objectives and KPIs.

B. Process Quality MS Tube / Steel Manufacturing

1. Monitor quality throughout raw material receipt, slitting, forming, ERW welding, sizing, cutting, and finishing.
2. Ensure dimensional accuracy, wall thickness, length, straightness, ovality, weld integrity, and surface finish.
3. Establish process inspection checkpoints and control plans for critical manufacturing operations.
4. Monitor welding parameters, mill settings, tooling condition, and process deviations.
5. Ensure proper inspection and testing of incoming HR/CR coils, strips, and other raw materials.
6. Coordinate with Production and Maintenance teams to eliminate recurring defects.
7. Analyze defects such as weld defects, cracks, dents, scratches, dimensional variation, and surface imperfections.

C. Galvanizing Quality Control

1. Monitor galvanizing process parameters and coating quality.
2. Ensure compliance with applicable coating thickness and adhesion requirements.
3. Control zinc coating defects such as bare spots, dross inclusions, runs, lumps, and uneven coating.
4. Monitor zinc bath temperature, bath chemistry, and other relevant process parameters.
5. Ensure proper inspection of galvanized products and maintain traceability of test results.
6. Coordinate corrective actions to reduce zinc consumption, rejection, rework, and coating-related customer complaints.

D. Testing, Inspection & Laboratory

1. Establish inspection and testing procedures for raw materials, in-process products, and finished goods.
2. Ensure availability and maintenance of testing facilities and inspection equipment.
3. Monitor mechanical testing, chemical analysis, weld testing, coating thickness testing, and dimensional inspection as applicable.
4. Ensure timely calibration and verification of measuring instruments and testing equipment.
5. Review inspection reports, test certificates, and product release documentation.
6. Ensure product identification, batch traceability, and retention of quality records.

E. Customer Quality & Supplier Development

1. Handle customer complaints, quality rejections, returns, and warranty-related issues.
2. Conduct root cause analysis using 5 Why, Fishbone Diagram, 8D, and other problem-solving tools.
3. Implement corrective and preventive actions and verify their effectiveness.
4. Coordinate with customers for quality audits, technical discussions, and product approvals.
5. Evaluate supplier quality performance and drive supplier corrective actions.
6. Develop suppliers through audits, inspection improvements, and process capability enhancement.

F. Continuous Improvement & Cost Control

1. Reduce internal rejection, rework, scrap, customer complaints, and cost of poor quality.
2. Drive Kaizen, 5S, Poka-Yoke, SPC, FMEA, and other continuous improvement initiatives.
3. Establish measurable quality KPIs and monitor performance against targets.
4. Improve first-pass yield, process capability, and product consistency.
5. Identify quality-related cost-saving opportunities without compromising product specifications.
6. Benchmark quality performance and implement best practices across production lines.

G. Team Leadership & Coordination

1. Lead, guide, and develop the QA/QC team, including engineers, inspectors, and laboratory personnel.
2. Define departmental objectives, responsibilities, and performance standards.
3. Conduct training on inspection techniques, quality tools, product standards, and customer requirements.
4. Coordinate with Production, Maintenance, Purchase, Dispatch, Sales, and senior management.
5. Ensure adequate manpower, testing facilities, and inspection resources.
6. Promote a zero-defect mindset and quality ownership among all employees.

2. Key Performance Indicators (KPIs)

• Customer complaints and customer rejection rate.
• Internal rejection and rework percentage.
• First-pass yield and process capability.
• Supplier rejection rate.
• Cost of poor quality.
• Audit non-conformities and closure timelines.
• On-time completion of inspections and testing.
• Calibration compliance.
• Reduction in recurring defects.
• Customer satisfaction and product conformity.

3. Required Technical Skills

• MS tube / ERW pipe manufacturing and steel processing.
• Hot-dip galvanizing and zinc coating quality control.
• ISO 9001 Quality Management System.
• BIS/ISI product standards and customer specifications.
• 7 QC Tools, SPC, FMEA, MSA, 8D, CAPA, and root cause analysis.
• Mechanical testing, dimensional inspection, and material testing.
• Quality audits, control plans, inspection plans, and process documentation.
• SAP/ERP, MS Excel, MIS, and quality data analysis.

4. Candidate Profile

• Strong experience in a steel, MS tube, ERW pipe, or galvanizing manufacturing plant.
• Proven experience in managing plant-level QA/QC operations.
• Ability to handle customer audits, technical complaints, and product approvals independently.
• Strong leadership, analytical thinking, decision-making, and problem-solving skills.
• Experience in reducing rejection, improving productivity, and maintaining consistent product quality.
• Willingness to work closely with Production and other departments to achieve plant quality targets.