Workshop QA Engineer (Medium & Heavy Structural Fabrication)

Role & responsibilities

Material and Incoming Inspection

• Verify raw material (plates, sections, pipes, hollow sections, bolts, consumables) against PO, drawings and specification.
• Check Mill Test Certificates (MTC), heat numbers and grade compliance (e.g., IS 2062, ASTM A36/A572, EN 10025 S355) and ensure traceability and material identification through cutting and fabrication.
• Verify welding consumables (type, batch, storage, baking and issue control) and approve receiving inspection reports.
• Raise rejection or non-conformance reports for deviating material.

Fabrication Process Inspection

• Study and interpret GA drawings, shop/fabrication drawings, BOMs, cutting plans and weld maps.
• Inspect cutting, edge preparation, bevel angle, root gap and root face, drilling, punching and straightening.
• Carry out stage-wise inspection of fit-up and assembly before welding, releasing the job only after verifying alignment, gaps, tack welds and cleanliness.
• Monitor distortion control, pre-heat and inter-pass temperature, and sequence of welding on heavy sections.
• Maintain a stage-wise inspection plan (ITP) and hold/witness points for every job.

Welding Inspection

• Verify availability and validity of WPS, PQR and welder qualification records (WPQ) before work starts, and ensure only qualified welders work on the applicable joints.
• Monitor welding parameters (current, voltage, travel speed, heat input), electrode/wire handling and shielding gas, as per the WPS.
• Perform visual inspection of welds (profile, undercut, porosity, overlap, spatter, cracks, incomplete fusion, weld size and leg length) using weld gauges, as per the applicable code and acceptance criteria.
• Maintain a welder performance record and identify repeat defects and rejection rates by welder and process (SMAW, GMAW/MAG, FCAW, SAW).

NDT Coordination

• Prepare NDT requirement lists and weld NDT plans (VT, MPT, DPT, UT, RT) as per the client specification, drawing and code.
• Coordinate with NDT agencies, witness testing where required, and review reports for acceptance.
• Track rejected welds through repair, re-inspection and re-test, and close the loop with documented evidence.
• Review NDT personnel qualification (ASNT SNT-TC-1A / ISO 9712) and procedures.

Dimensional Inspection

• Carry out dimensional checks of fabricated members and assemblies against drawing tolerances: length, camber, sweep, twist, squareness, flatness, hole pitch and position, flange tilt and web verticality.
• Perform trial assembly/match-marking inspection of connections, base plates, bolted splices and bracings where required.
• Use calibrated instruments: measuring tapes, vernier calipers, steel rules, levels, plumb bobs, bevel protractor, feeler and radius gauges and, where available, total station or laser equipment.
• Ensure that all measuring instruments are calibrated and within the calibration validity.

Surface Preparation, Painting and Coating Inspection

• Inspect blasting quality (Sa 2 typically), surface profile, soluble salts and cleanliness, as per ISO 8501/8502/8503 or SSPC.
• Monitor ambient conditions (dew point, relative humidity, surface temperature), paint batch and shelf life, mixing and pot life.
• Measure wet film thickness (WFT) and dry film thickness (DFT), and check adhesion, cure and visual finish for each coat, as per the paint system specification.
• Verify galvanizing thickness and finish where hot-dip galvanizing is specified.

Final Inspection,

• Marking and Dispatch Conduct final inspection, check marking and identification of members, and verify completeness against BOM and packing list.
• Prepare the final inspection release note and obtain client / TPI sign-off on hold and witness points.
• Check loading, packing and transit protection to prevent damage to coatings and members.

Non-Conformance and Corrective Action

• Raise Non-Conformance Reports (NCR) with clear description, root cause and proposed corrective and preventive action (CAPA).
• Track rework and repair procedures, verify implementation and close NCRs on time.
• Analyse recurring defects and suggest process improvements to production.

Quality Documentation

• Prepare and maintain inspection records: material receipt, fit-up, welding visual, dimensional, NDT, painting and final inspection reports.
• Compile the final Quality Dossier / Manufacturing Record Book (MRB) per job: MTCs, WPS/PQR/WPQ, NDT reports, calibration certificates, inspection reports, NCR closures and release notes.
• Maintain document control, traceability matrix and revision control of drawings.
• Submit daily/weekly quality reports and rejection/rework statistics to management.

Client,TPI and Audit

• Interface Plan and conduct inspections with client representatives and Third-Party Inspection agencies; manage inspection call-ups and offer notices. Support internal and external quality audits (ISO 9001, ISO 3834, EN 1090 or client audits).
• Ensure compliance with the project Quality Plan, ITP and client specifications.

Safety and Housekeeping

• Follow and promote workshop safety practices (PPE, hot-work, lifting and rigging, grinding and blasting safety).
• Ensure the inspection area, tools and calibrated equipment are properly maintained.

Preferred candidate profile

• Diploma or Bachelor's degree in Mechanical, Production, Metallurgical or Civil/Structural Engineering.
• 58 years of hands-on quality inspection experience in medium and heavy structural fabrication (e.g., steel buildings, PEB heavy sections, industrial structures, bridges, pipe racks, towers, plant structures, platforms and heavy equipment supports).
• Proven experience in welding inspection and fabrication process control on heavy plates and sections.
• Strong exposure to dimensional inspection and drawing reading.
• Experience preparing quality documentation and final dossiers for client submission.