Supervisor, Manufacturing Process Quality

Job Summary

Line Quality Manager - Switchgear (Circuit Breakers & Vacuum Interrupters). Seeking a hands-on leader to own line quality for MV switchgear. Must have strong experience in Control Plans, PFMEA, RCA/CAPA (8D/A3), SPC/MSA, ISO 9001, SAP QM, PPAP, and in-depth product/test knowledge of circuit breakers & vacuum interrupters. Responsibilities include driving FPY, managing inspections, supplier quality/APQP, audits, and robust documentation. B.E./B.Tech (Electrical/Mechanical, experience in switchgear manufacturing; Lean Six Sigma preferred.

Role Purpose

Own end-to-end in-line quality for switchgear assembly and testing operations, driving defect prevention, robust process controls, and rapid problem resolution. Lead Quality at the shopfloor to ensure safe, compliant, and reliable products that meet customer requirements and applicable standards.

Key Responsibilities

• Line Quality Ownership: Ensure First Pass Yield (FPY) and Right-First-Time across assembly, in-process, and final testing; maintain robust control of CTQ parameters.
• Control Plans & PFMEA: Create, maintain, and audit Process FMEA and Control Plans; ensure controls are implemented and effective at the line.
• Problem Solving (RCA/CAPA): Lead high-impact root cause analysis and corrective actions using 8D, A3, DMAIC, 5-Why, Fishbone; verify CAPA effectiveness and sustainment.
• Inspection Governance: Define and execute incoming, in-process, and final inspection plans; supervise usage decisions, and non-conformance management.
• Quality Systems & Compliance: Ensure adherence to ISO 9001 QMS; support audits and continuous improvement. (Exposure to ISO 14001/ISO 45001 is a plus.)
• Product & Test Knowledge: Oversee assembly and testing of MV circuit breakers, vacuum interrupters, and associated switchgear modules; ensure compliance to relevant IEC/IS standards and type/routine tests.
• Quality Tools & Analytics: Deploy SPC, MSA (GR&R), capability studies (Cp/Cpk), control charts, drive data-based decisions.
• Supplier & PPAP: Collaborate with SQA for APQP/PPAP of critical components; qualify changes; monitor supplier PPM and incoming quality.
• Documentation & Change Control: Inspection Plans, SOPs, WI, ECNs; ensure controlled documents on the line.
• Digital & Systems: Use SAP (QM) for inspection lots, notifications, NCRs, usage decisions, and production traceability; drive digitized quality dashboards.
• Training & Culture: Coach operators and line leaders on defect prevention, standard work, and safe quality practices; run layered process audits (LPA).
• Customer Focus: Support field returns analysis, warranty issues, and customer audits; drive lesson-learned back into the line.

Must-Have Technical Skills

• Control Plan / PFMEA (Process FMEA)
• RCA / CAPA using 8D / A3 methodologies
• Usage of Quality Tools: SPC, MSA (GR&R), 5-Why, Fishbone, Pareto, Control Charts, Cp/Cpk
• Product Knowledge: Circuit Breakers / Vacuum Interrupters (assembly, functional testing, dielectric/mechanical endurance, contact timing)
• Knowledge of ISO Standards: ISO 9001 (QMS); exposure to ISO 14001/45001 preferred
• Inspection Skills: Incoming/In-process/Final; electrical tests (dielectric/primary injection), mechanical checks, torque, micro-ohm, timing analyzer
• SAP: Hands-on with SAP QM (inspection plans, lots, notifications, usage decision)
• PPAP: Understanding and execution with suppliers; documentation review and approvals

Additional Requirements (Recommended)

• APQP and Control of Special Characteristics (CTQ/Critical-to-Quality)
• IEC/IS Standards Awareness: IEC 62271
• Type & Routine Tests: Short-circuit, dielectric, thermal, mechanical endurance, routine verification for circuit breakers and vacuum interrupters
• Metrology & Tools: Calibrated instruments usage; torque tools, micro-ohm meters, hipot testers, timing analyzers; gauge control
• Change Management: ECN/ECO governance, deviation/concession control, DFM/A with Manufacturing
• Lean/Six Sigma: Green Belt (preferred) with demonstrated DMAIC projects
• Audit Experience: LPA, internal/external audits, customer audits; audit closure management
• ESD & Safety Practices: Electrical safety at test bays; lock-out/tag-out (LOTO) awareness
• Documentation Rigor: Strong technical writing for SOPs, WI, CAPA reports, 8D dossiers

Education & Experience

B.E./B.Tech in Electrical/Mechanical (Electrical preferred). Proven leadership in PFMEA/Control Plans, CAPA, and audit readiness.

Key Performance Indicators

• FPY/RTY improvement
• Internal/External PPM, Customer Returns/Warranty reduction
• CAPA Closure Lead Time and Effectiveness
• Supplier Quality Metrics: Incoming PPM, PPAP on-time, audit scores
• Audit Outcomes: No. of findings and closure time
• COPQ (Cost of Poor Quality) reduction

Work Environment

• Shop-floor presence: 60% for gemba, LPA, and real-time problem solving
• Shift/Weekend support: As needed for production continuity
• Location: Plant/Unit
• Travel: Occasional to suppliers/customers/test labs

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