Quality Manager - Vehicle Assembly

Job Description

Job Summary:

The Quality Manager Vehicle Assembly will be responsible for ensuring product quality throughout the electric two-wheeler assembly process by implementing in-process quality controls, conducting inspections, analyzing defects, driving corrective actions, and ensuring compliance with quality standards. The role involves close coordination with Production, Engineering, Supplier Quality, and Service teams to deliver defect-free vehicles and continuously improve assembly quality performance.

Key Responsibilities

In-Process Quality Control (IPQC)

Monitor and control quality at various stages of vehicle assembly.

Conduct visual, dimensional, functional, and electrical inspections.

Verify adherence to SOPs, Control Plans, Process Check Sheets, and Work Instructions.

Ensure critical assembly parameters such as torque, fitment, alignment, and electrical connections meet specifications.

Conduct layered process audits and process compliance checks.

Vehicle Quality Inspection

Perform inspections of assembled vehicles before final testing and dispatch.

Verify quality of chassis, suspension, braking systems, electrical systems, motor, controller, wiring harness, and battery pack integration.

Ensure all customer, regulatory, and internal quality requirements are met.

Validate assembly quality against engineering drawings and standards.

Defect Identification & Root Cause Analysis

Identify and document defects, non-conformities, and process deviations.

Perform Root Cause Analysis using:

8D Methodology

5 Why Analysis

Fishbone Diagram

7 QC Tools

Implement and monitor Corrective and Preventive Actions (CAPA).

Drive defect reduction and first-pass yield improvement initiatives.

Battery & Electrical Quality Assurance

Inspect battery pack installation and vehicle electrical integration.

Verify battery-related parameters such as:

OCV

Voltage

IR (Internal Resistance)

SOC

Battery connectivity and safety compliance

Ensure proper functioning of BMS communication and vehicle diagnostics.

Monitor battery charging and discharging process compliance.

Process Quality Assurance

Ensure process adherence as per IATF 16949 standards.

Verify implementation of Poka-Yoke systems and process controls.

Monitor quality KPIs including:

FPY (First Pass Yield)

Rework

Rejection

COPQ

Customer Complaints

Conduct periodic process audits and quality reviews.

Documentation & Reporting

Maintain inspection records, quality reports, and audit documentation.

Generate daily quality MIS and defect analysis reports.

Maintain Control Plans, PFMEA, Process Flow Charts, and Quality Records.

Support traceability and record retention requirements.

Ensure ISO/IATF documentation compliance.

Continuous Improvement

Lead quality improvement projects and Kaizen activities.

Analyze defect trends and implement preventive measures.

Participate in Quality Circle (QCC) activities.

Support implementation of Lean Manufacturing and Six Sigma methodologies.

Drive reduction in warranty and field failure issues.

Supplier & Customer Quality Support

Support incoming quality inspections for purchased components.

Coordinate with Supplier Quality teams for defect containment and corrective actions.

Participate in customer complaint investigations and field quality analysis.

Support closure of warranty-related quality concerns.

Training & Development

Train production operators on quality standards and defect awareness.

Conduct skill evaluations and certification programs.

Develop quality awareness programs across manufacturing operations.

Support competency development of shop-floor personnel.

Cross-Functional Collaboration

Work closely with Production, Manufacturing Engineering, R&D, Supplier Quality, and Service teams.

Participate in New Product Introduction (NPI) quality activities.

Support engineering changes, process validation, and production ramp-up activities.

Provide quality feedback for design and process improvements.

Required Skills & Competencies

Technical Skills

Strong understanding of vehicle assembly quality systems.

Knowledge of electric vehicle architecture and assembly processes.

Good understanding of:

Battery Pack Systems

BMS

Motor

Controller

Wiring Harness

Vehicle Electrical Systems

Expertise in quality inspection techniques and process audits.

Knowledge of PFMEA, Control Plans, APQP, PPAP, SPC, and MSA.

Strong understanding of IATF 16949 requirements.

Quality Tools

7 QC Tools

8D Problem Solving

CAPA

Root Cause Analysis

Fishbone Diagram

Why-Why Analysis

Poka-Yoke

Statistical Process Control (SPC)

Software & Tools

MS Excel

PowerPoint

ERP / SAP Systems

Quality Management Systems

Inspection and Testing Equipment

Vehicle Diagnostic Tools (preferred)

Soft Skills

Strong analytical and problem-solving skills.

Excellent observation and attention to detail.

Effective communication and stakeholder management.

Ability to handle multiple priorities in a fast-paced manufacturing environment.

Strong teamwork and leadership capabilities.

Preferred Qualifications

Experience in Electric Vehicle Manufacturing.

Exposure to Battery Pack Assembly and Testing.

Experience in Vehicle Assembly Quality or Process Quality.

Knowledge of High Voltage Safety Requirements.

Experience with Customer Quality and Warranty Analysis.

Internal Auditor Certification (IATF 16949) is an added advantage.

Role & Responsibilities

Role: Quality Manager – Vehicle Assembly

Industry Type: Automobile (Electric Vehicle / EV)

Department: Quality Assurance / Manufacturing Quality

Employment Type: Full Time, Permanent

Role Category: Quality Engineering

Education:

UG: B.Tech / B.E. in Mechanical Engineering, Automobile Engineering, Electrical Engineering, Electronics Engineering, Production Engineering, Industrial Engineering, Mechatronics, or related disciplines

Diploma candidates with relevant automotive or EV quality experience may also be considered.