Assistant Manager-BIW Quality

Montra Electric; Chennai District; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Montra Electric seeks a Quality Assurance Lead for BIW and Paint processes. You will lead QA activities, enforce SOPs, and drive process improvements across the plant to ensure defect-free products and compliant operations.

The role requires hands-on use of MPPAP, FMEA, Control Plans, SPC, MSA and 8D methodologies, daily data review, and collaboration with cross-functional teams to close CAPAs and sustain QMS excellence.

Qualifications

• Experience with BIW and Paint quality processes.
• Strong knowledge of QMS and process improvement.
• Proficiency in SPC, MSA and FMEA.

Responsibilities

• Lead QA activities for BIW and Paint to uphold standards and compliance.
• Implement QC tools like MPPAP, FMEA, Control Plans and SPC.
• Conduct process, product and layer audits in the plant.
• Drive in-process quality with SOPs and process documentation.
• Monitor daily rejection rates and drive CAPAs.
• Ensure compliance to QMS and promote continuous improvement.
• Perform SPC and MSA data monitoring to verify processes.
• Utilize 8D and QC story methods for root cause analysis.
• Collaborate with cross-functional teams to align with assembly requirements.
• Oversee assembly processes per drawings and SOPs to ensure defect-free output.
• Identify gaps and implement corrective actions with CFT.
• Manage Engineering Change Management to protect product integrity.
• Daily CTQ & Z-stage audits to uphold quality benchmarks.
• Establish and monitor Pp/Ppk, Cp/Cpk for process capability.
• Work with field teams to resolve customer issues to zero defects.

Skills

BIW QA

Quality Assurance

Root Cause Analysis

SOP Adherence

Cross-functional Collaboration

Tools

MPPAP

FMEA

Control Plans

SPC

MSA

8D Methodology

Job description

Role & responsibilities

1. Lead and manage quality assurance activities specific Body-in-White (BIW) and Paint processes to maintain high standards and compliance.

2. Implement and oversee quality control tools and methodologies such as MPPAP, FMEA, Control Plans, MSA, and SPC to systematically identify and mitigate risks throughout the manufacturing process.

3. Conduct thorough process audits including overall process audits, product audits, and layer audits within the plant environment to ensure adherence to quality standards and continuous improvement.

4. Drive the quality assurance function within BIW/Weld shop, working closely with cross-functional teams to enforce in-process quality assurance as per standard operating procedures (SOPs) and process documentation.

5. Monitor and analyse daily internal rejection rates; proactively initiate corrective and preventive actions to enhance product quality and reduce defects.

6. Ensure strict compliance to Quality Management Systems (QMS), support its effective implementation across manufacturing operations and promote ongoing improvement initiatives to address routine quality challenges.

7. Perform regular process audits and data monitoring using Statistical Process Control (SPC) and Measurement System Analysis (MSA) studies to verify adherence to defined processes and standards.

8. Utilise structured problem-solving techniques including 8D and QC story methodologies to investigate issues, interpret engineering drawings, and analyse rejection data to drive root cause resolution.

9. Work in close partnership with cross-functional teams (CFT) to ensure alignment with assembly quality requirements, facilitating seamless execution of quality strategies.

10. Oversee the application of assembly processes as per technical drawings and SOPs, guaranteeing delivery of defect-free products to customers.

11. Proactively identify process gaps and quality concerns, implementing timely corrective measures in coordination with CFT to enhance manufacturing effectiveness.

12. Manage and control the Engineering Change Management Process to maintain product integrity and facilitate smooth transitions during product updates.

13. Conduct daily audits focusing on Critical to Quality (CTQ) parameters and zero (Z) stage audits to maintain stringent adherence to quality benchmarks.

14. Establish initial Process Capability indices (Pp/Ppk) and consistently monitor ongoing capability (Cp/Cpk) to ensure process stability and capability improvement over time.

15. Collaborate effectively with the field and application teams to manage and resolve customer complaints promptly, targeting zero-defect and low MIS score outcomes.

16. Work with ME team to establish the Equipment/Process contingency plan to support continued production.

Preferred candidate profile

1. Sound knowledge on Bodyshop welding fixture standard maintenance for fixture correction.


2. Sheet metal reworks for spot welding and MIG welding for skin panel.


3. Dimensional study knowledge required for part level and assembly level correction to meet the PIST.


4. PCF gauge concept knowledge and part validation at PCF gauge.


5. Good knowledge on start-up checks after shut down, layered process audit & lesson learnt documentation.


6. Regular conduct product audit for BIW assembly, identify the risk areas & drive mitigation plan.