Quality Assurance Engineer

ACURA SOLUTIONS LTD; Maharashtra; On-site; INR 600,000 - 900,000; Full time

Job summary

ACURA SOLUTIONS LTD in Maharashtra, India, seeks a Quality Assurance Engineer to ensure the quality, reliability, and compliance of battery packs, forklifts and material handling equipment across incoming inspection, manufacturing, assembly, testing and final dispatch.

The role involves inspecting incoming materials, components and sub-assemblies; conducting supplier and internal audits; leading CAPA and root-cause analysis; maintaining quality records; and ensuring adherence to drawings, specs

Job description

Job Summary

We are looking for a Quality Assurance Engineer responsible for ensuring the quality, reliability, and compliance of battery packs, forklifts, and material handling equipment throughout incoming inspection, manufacturing, assembly, testing, and final dispatch.

Key Responsibilities

• Incoming Quality Assurance
• Inspect incoming raw materials, components, battery cells, BMS, connectors, cables, mechanical parts, electrical/electronic components, and bought-out assemblies.
• Prepare and maintain incoming inspection standards, specifications, sampling plans, and check sheets.
• Conduct supplier quality audits and evaluate supplier performance.
• Raise and monitor Supplier Corrective Action Requests (SCAR) for quality issues.
• Support supplier development and continuous quality improvement.
• Battery Pack Quality
• Perform quality inspection of battery packs and sub-assemblies.
• Verify battery cell/module assembly, busbars, connectors, wiring, insulation, torque, polarity, labeling, and mechanical assembly.
• Verify BMS installation, configuration, communication, alarms, protections, and basic functional parameters.
• Monitor battery pack testing such as voltage, current, insulation resistance, continuity, charging/discharging, and functional performance as applicable.
• Ensure compliance with approved drawings, BOMs, work instructions, specifications, and test procedures.
• Identify and investigate battery pack defects, including assembly, electrical, mechanical, and functional failures.
• Forklift Material Handling Equipment Quality
• Conduct in-process and final inspections of forklifts, pallet trucks, stackers, reach trucks, AGVs/AMRs, and other material handling equipment.
• Inspect mechanical, electrical, hydraulic, and electronic assemblies.
• Verify critical parameters such as steering, braking, lifting/lowering, travel, load handling, safety interlocks, emergency stop, alarms, displays, and operator controls.
• Perform functional and performance testing according to approved test procedures.
• Ensure product conformity with engineering drawings, specifications, and applicable standards.
• Process Quality
• Conduct stage-wise inspections and audits on the production line.
• Establish quality checkpoints and control plans for critical processes.
• Monitor Critical-to-Quality (CTQ) characteristics and process parameters.
• Prepare and maintain PFMEA, Control Plan, SOPs, inspection standards, and quality check sheets.
• Implement mistake-proofing/Poka-Yoke wherever applicable.
• Identify process deviations and coordinate corrective actions with Production and Engineering.
• Testing Validation
• Develop and execute inspection and testing procedures for battery packs and material handling equipment.
• Maintain test records and ensure calibration of measuring and testing equipment.
• Support product validation, reliability testing, and endurance testing.
• Analyze test failures and coordinate root-cause investigations.
• Ensure traceability of critical components, battery packs, and finished products.
• Non-Conformance Root Cause Analysis
• Identify, document, segregate, and control non-conforming products.
• Lead root-cause analysis using 5 Why, Fishbone/Ishikawa, 8D, Pareto, and other quality tools .
• Implement and verify Corrective and Preventive Actions (CAPA).
• Monitor recurring defects and drive permanent corrective actions.
• Maintain NCR, rejection, rework, scrap, and defect data.
• Customer Quality
• Investigate customer complaints and field failures related to battery packs and material handling equipment.
• Coordinate with Service, Engineering, Production, and suppliers for complaint resolution.
• Prepare 8D reports and corrective-action reports.
• Monitor warranty/field failure trends and implement preventive actions.
• Support customer audits and quality reviews.
• Quality Systems Compliance
• Ensure adherence to the organization's QMS and applicable quality procedures.
• Support ISO 9001 implementation and internal/external audits.
• Maintain quality records, inspection reports, test reports, calibration records, and traceability documents.
• Support compliance with applicable battery, electrical, machinery, and material-handling equipment standards and customer requirements.
• Participate in continuous improvement initiatives.