QPC Head, BRW

Calderys; Khordha; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Calderys in Khordha seeks a Quality Assurance Manager with a minimum of 12 years' experience in the refractory industry. The role involves overseeing quality control processes for refractory products, ensuring compliance with industry standards, and driving continuous improvement initiatives.

The ideal candidate will have a B.Tech/M.Tech degree in Ceramic Technology/Engineering and strong leadership skills. Candidates should possess hands-on experience in manufacturing processes and a deep understanding of refractory materials.

Qualifications

• Minimum 12 years' experience in a QA & QC role in the refractory industry.
• Hands-on experience in shaped refractory manufacturing and kiln operations.
• Strong understanding of refractory brick chemistry and thermomechanical behavior.

Responsibilities

• Develop and implement quality plans for refractory products.
• Oversee end-to-end refractory brick manufacturing.
• Ensure effective control of defects.

Skills

Quality assurance

Refractory industry knowledge

Analytical skills

Problem-solving skills

Communication skills

Education

B.Tech/M.Tech (Ceramic Technology/Engineering)

Tools

ISO standards

Lean manufacturing

Six Sigma

Job description

Responsibilities

• Develop and implement quality plans for shaped refractory products for raw materials, processing, firing, and finished goods.
• Oversee end-to-end refractory brick manufacturing: crushing, grinding, batching, mixing, shaping (pressing/extrusion), drying, firing, and finishing.
• Monitor incoming raw material quality and ensure conformance to chemical, physical, and mineralogical specifications.
• Ensure traceability, documentation and compliance with ISO 9001, IMS, and customer‑specific quality requirements.
• Define CTQs, control plans, inspection plans, SOPs, and testing protocols for shaped products.
• Drive standardization of quality practices across shifts and product lines.
• Conduct supplier audits and periodic performance reviews.
• Lead RM qualification, alternate source development, and cost‑optimization initiatives without compromising quality.
• Ensure effective control of defects such as cracks, laminations, warpage, under/overfiring, dimensional deviations, and strength variation.
• Ensure testing of shaped refractories as per IS/ASTM/ISO standards (AP/BD, CCS, PLC, HMOR, refractoriness, RUL, thermal shock, creep, etc.).
• Approve final product release and COA issuance.
• Control rejection rates and drive reduction through root cause analysis and corrective actions.
• Ensure timely evaluation and qualification of new raw materials through lab trials and industrial validation.
• Supervise calibration, maintenance, and validation of laboratory equipment to ensure reliability of results.
• Conduct testing and analysis of R&D samples, pilot batches, and customer trial samples.
• Reduce quality complaints through root cause analysis and corrective/preventive actions.
• Handle customer complaints related to shaped products and lead failure analysis (RCA, CAPA).
• Customization of products / cost‑savings exercises for products.
• Coordinate with cross‑functional teams (production, procurement, R&D, Sales, site teams) to resolve quality issues of raw materials and finished products.
• Training and mentoring QA/QC teams to upgrade technical knowledge and ensure skill development.
• Conduct vendor audits, quality evaluation, and qualification of raw material suppliers.
• Support new product development with performance validation and scale‑up trials.
• Promote sustainability initiatives such as reclaim material utilization without performance loss.
• Support Sales with technical justifications, datasheets, and benchmarking against competitors.
• Proven leadership in team handling, mentoring, and capability building.

Profile and Competencies

• B.Tech/M.Tech (Ceramic Technology/Engineering) from a reputed Ceramic Institute.
• Minimum 12 years' experience in a QA & QC role of a reputed Refractory industry; experience in Refractory Shaped products (brick industry) is preferred.
• Knowledge in ceramics and refractories.
• Sound knowledge of refractory brick manufacturing processes, including raw material evaluation and selection, control of critical process parameters, and final product testing and inspection.
• Strong understanding of refractory brick chemistry, mineralogy, and thermomechanical behavior.
• Hands‑on experience with shaped refractory manufacturing and kiln operations.
• Ability to interpret test data and link it to process behavior.
• Ensure consistent product quality through strict adherence to SOPs and control plans.
• Analytical and problem‑solving skills.
• Excellent written and oral communication.
• Knowledge of refractory property‑performance correlation.
• Hands‑on experience in various testing and characterization methods pertaining to refractories.
• Knowledge of quality standards (ISO, BIS, ASTM, DIN, EN) and certification processes.
• Familiarity with lean manufacturing, Six Sigma, Kaizens, and TQM principles.
• Strong cross‑functional collaboration, customer‑oriented mindset with focus on performance, reliability, and cost‑effectiveness.