Quality Test Engineer

Key Responsibilities

• Inspect and verify incoming materials, components, fabricated parts, electrical components, panels, assemblies, and finished products as per approved drawings, specifications, BOMs, and applicable standards.
• Perform Incoming Quality Control (IQC), In-Process Quality Control (IPQC), and Final Quality Control (FQC) activities.
• Review and verify electrical schematics, GA drawings, SLDs, wiring diagrams, BOMs, cable schedules, and technical specifications.
• Perform quality inspection and testing of PLC Panels, MCC Panels, HT Panels, LT Panels, Control Panels, APFC Panels, PCC Panels, and other electrical/automation panels.
• Conduct panel inspection for:
  
• Panel dimensions, enclosure, mounting, and workmanship.
• Component make, model, rating, and quantity against BOM.
• Busbar size, rating, insulation, supports, clearances, and connections.
• Cable sizing, ferruling, termination, dressing, and routing.
• Earthing and bonding arrangements.
• Component mounting and identification/labeling.
• Tightness of electrical connections and terminal connections.
• Wiring continuity and correctness as per approved drawings.
• Proper segregation of power, control, instrumentation, and communication wiring.
• Interlocks, indications, push buttons, selector switches, relays, contactors, and protection devices.
• Panel cleanliness, painting, gland plates, doors, locks, and overall workmanship.

Panel Testing & Functional Testing

• Carry out electrical and functional testing of PLC, MCC, HT, and LT panels as per approved test procedures, drawings, specifications, and customer requirements.
• Perform point-to-point wiring and continuity checks for control and power circuits.
• Conduct Insulation Resistance (IR) testing using a suitable insulation resistance tester/Megger.
• Perform High Voltage / Dielectric Withstand (Hi-Pot) testing, wherever applicable and as per approved test procedures and applicable standards.
• Perform Earth Continuity and Earth Resistance checks as applicable.
• Verify phase sequence, polarity, voltage levels, and power/control circuit connections.
• Test and verify MCBs, MCCBs, ACBs, contactors, overload relays, protection relays, fuses, timers, control relays, and other protection/control devices.
• Verify operation of electrical and mechanical interlocks.
• Conduct functional testing of PLC panels, including:
  
• PLC I/O point verification.
• Digital Input (DI) and Digital Output (DO) testing.
• Analog Input (AI) and Analog Output (AO) verification.
• Sensor and actuator signal verification.
• PLC-to-HMI communication checks.
• Communication/network checks, where applicable.
• Alarm, trip, permissive, and interlock verification.
• Conduct functional testing of MCC panels, including motor feeder operation, starter circuits, DOL/star-delta starters, contactors, overload protection, interlocks, and indications.
• Conduct inspection and testing of HT/LT panels, including protection, metering, interlocks, breaker operation, indications, control circuits, and other applicable functional checks.
• Verify VFD, soft starter, servo drive, power supply, SMPS, and other automation components integrated into control panels.
• Conduct FAT (Factory Acceptance Testing) with the customer/client or consultant, where required.
• Prepare and maintain Panel Inspection Reports, Test Reports, FAT Reports, Check Sheets, and Quality Records.
• Record test results, identify deviations/non-conformities, and coordinate with the electrical/automation engineering and production teams for corrective actions.
• Ensure all identified defects are rectified and re-tested before final inspection and dispatch.
• Ensure testing instruments such as multimeter, clamp meter, insulation resistance tester, high-voltage tester, earth tester, and other measuring equipment are calibrated and have valid calibration certificates.

Technical Skills Additional Requirements

• Strong knowledge of electrical panel manufacturing, wiring, testing, and inspection.
• Practical experience in testing PLC, MCC, HT, LT, PCC, APFC, and control panels.
• Ability to read and interpret electrical schematics, SLDs, GA drawings, wiring diagrams, control circuit diagrams, and panel layouts.
• Knowledge of PLC I/O testing, HMI interfaces, VFDs, sensors, relays, contactors, protection devices, and industrial communication systems.
• Knowledge of electrical safety procedures and safe practices during panel testing.
• Familiarity with applicable IEC/IS standards and customer-specific testing requirements.
• Experience in conducting FAT and pre-dispatch inspections will be an added advantage.