Quality Assurance Manager

Samyu Glass Pvt Ltd; YSR Kadapa; Sur place; INR 1 800 000 - 3 000 000; Plein temps

Résumé du poste

Samyu Glass Pvt Ltd. seeks a hands-on Quality Manager to lead the plant's quality program across raw material to dispatch. You will build and sustain the QMS, monitor KPIs, and drive improvements with cross-functional teams.

The role requires strong leadership, customer-facing experience, and a proven track record in reducing defects and process variation in glass manufacturing.

Qualifications

• Experience leading quality teams in manufacturing.
• Strong knowledge of quality tools and problem solving.
• Experience with customer audits and supplier quality is a plus.

Responsabilités

• Lead and maintain the Quality Management System (QMS) in the glass container plant.
• Drive root-cause analysis and CAPA to reduce defects and customer complaints.
• Coordinate with Production, Maintenance and other functions to ensure product conformance and timely release.

Connaissances

Quality leadership

Customer handling

Cross-functional teamwork

Root cause analysis

Formation

Bachelor's degree in Engineering

Outils

Electronic inspection systems

Description du poste

Monitor and control the quality parameters of the container forming process, including:

• Gob weight and gob temperature
• Section-wise process parameters
• Blank and blow mould conditions
• Body dimensions
• Wall thickness
• Verticality
• Deflection
• Thermal shock-related issues
• Cracks and checks
• Mould-related defects
• Forming process stability.

Work closely with Production, Maintenance and Hot-End teams to identify and eliminate recurring defects.

• Monitor annealing process parameters.
• Ensure correct lehr temperature profile and process conditions.
• Monitor residual stress and annealing quality.
• Investigate breakage and thermal-stress-related defects.
• Coordinate with Production and Maintenance for corrective actions.

4. Cold-End Quality & Inspection

Lead the cold-end quality function and ensure effective inspection of finished glass containers.

Critical quality parameters include:

• Container weight
• Height
• Diameter
• Capacity
• Wall thickness
• Base thickness
• Verticality
• Cracks/checks
• Seeds/blisters
• Cord
• Black spots
• Deformation

Ensure proper functioning and calibration of inspection equipment such as:

• Electronic inspection machines
• Vision inspection systems
• Dimensional inspection equipment
• Pressure testers
• Thermal shock testers
• Laboratory instruments.

5. Product Inspection & Release

• Establish inspection plans and sampling standards for all products.
• Ensure final product inspection before dispatch.
• Maintain product quality records and traceability.
• Authorize product release/rejection based on approved specifications.
• Control non-conforming products through proper identification, segregation and disposition.
• Ensure proper control of rejected and downgraded products.
• Monitor quality performance line-wise, machine-wise, section-wise and product-wise.

6. Customer Quality & Complaint Management

This is a key responsibility of the position.

• Act as the primary Quality contact for customers.
• Understand customer specifications and quality expectations.
• Review customer complaints and coordinate investigation.
• Conduct structured root-cause analysis using:
• 5 Why
• Fishbone Analysis
• 8D
• CAPA.
• Provide timely corrective and preventive action reports to customers.
• Monitor effectiveness of corrective actions.
• Participate in customer visits, audits, trials and technical discussions.
• Coordinate product approval and qualification with customers.
• Maintain customer-specific quality standards and specifications.
• Track customer complaints, rejection, returns and quality claims.

Preference should be given to candidates having direct experience in dealing with external customers, customer audits and customer complaint resolution.

7. Quality Management System

• Establish, implement and maintain the plant Quality Management System.
• Ensure compliance with applicable ISO and customer requirements.
• Prepare and maintain:
• SOPs
• Work instructions
• Quality plans
• Inspection standards
• Control plans
• Check sheets
• Quality records.
• Conduct internal quality audits.
• Ensure closure of audit observations.
• Drive continuous improvement in the Quality Management System.

8. Quality Data Analysis & Improvement

Develop and monitor quality KPIs such as:

• Customer complaints
• Defects per million / PPM where applicable
• Quality losses
• Downgraded production

Use statistical and analytical tools to identify trends and recurring problems.

Prepare daily, weekly and monthly quality performance reports for management.

• Lead cross-functional quality improvement teams.
• Identify chronic and recurring defects.
• Drive systematic root-cause analysis.
• Implement permanent corrective actions rather than temporary containment.
• Reduce internal rejection and customer complaints.
• Identify opportunities for:
• Process improvement
• Material optimization
• Yield improvement
• Cost reduction.
• Participate in improvement projects such as Kaizen, Six Sigma or other structured improvement initiatives.

10. Laboratory Management

• Calibration of laboratory equipment.
• Testing of raw materials and finished products.
• Glass chemical analysis.
• Physical and dimensional testing.
• Stress/annealing tests.
• Thermal shock tests.
• Pressure tests where applicable.
• Proper maintenance of laboratory records.
• Availability of testing facilities and consumables.

11. Calibration & Measurement System

• Establish calibration schedules for all measuring and testing equipment.
• Ensure calibration through approved agencies.
• Ensure traceability of measurement standards.
• Identify and control equipment found outside calibration limits.
• Conduct measurement system verification wherever required.

12. Packing & Dispatch Quality

• Ensure packing quality meets customer requirements.
• Monitor:
• Dividers/separators
• Strapping
• Labeling
• Product identification
• Ensure proper segregation and identification of rejected/non-conforming products.
• Coordinate with Packing, Stores and Dispatch teams to prevent quality issues reaching customers.

13. Supplier Quality Management

• Evaluate and monitor critical material suppliers.
• Review supplier quality performance.
• Participate in supplier audits where required.
• Establish supplier quality improvement plans.
• Monitor incoming rejection and supplier-related quality losses.

14. New Product Development & Trials

• Review customer drawings/specifications.
• Establish quality requirements for new products.
• Support mould trials and production trials.
• Develop inspection standards for new products.
• Validate dimensions and functional requirements.
• Prepare product quality documentation for customer approval.
• Support commercialization of new products.

15. Customer / External Audit Management

Lead preparation and coordination for:

• Statutory/third-party inspections
• Supplier/customer technical audits.

Ensure timely closure of audit observations and maintain proper evidence of compliance.

16. Team Management

• Lead and develop the Quality team.
• Define responsibilities and accountability for Quality Engineers, Inspectors and Laboratory personnel.
• Prepare manpower and shift requirements.
• Conduct training and competency development.
• Evaluate team performance.
• Establish strong ownership for quality at each manufacturing stage.
• Develop second-line Quality leadership.

17. Cross-Functional Responsibilities

The Quality Manager shall work closely with:

• Production
• Maintenance
• Instrumentation
• Electrical
• Packing
• Purchase
• Customer Service
• HR
• Management.

The role requires the ability to influence production and other functional teams without compromising quality standards.

18. Quality & Cost Improvement

The Quality Manager shall actively contribute to reduction of:

• Glass wastage
• Downgraded production
• Customer complaints
• Rework
• Packing-related losses.

Quality improvement should be driven with a focus on both customer satisfaction and manufacturing cost reduction.

19. Authority

The Quality Manager shall have authority to:

• Stop/hold dispatch of products not meeting specifications.
• Place non-conforming products under quality hold.
• Escalate critical quality issues to Plant Management.
• Initiate corrective and preventive actions.
• Recommend process changes to improve product quality.
• Participate in customer technical discussions.
• Approve routine quality inspection and testing procedures within the approved QMS.

20. Key Performance Indicators – KPI

Performance shall be evaluated based on:

• Customer complaint reduction.
• Quality loss reduction.
• Timely closure of CAPA/8D.
• Supplier quality improvement.
• Laboratory and calibration compliance.
• Quality system compliance.
• New product approval and successful trials.
• Reduction of recurring quality problems.
• Contribution to overall plant yield and productivity.

21. Qualification

• Bachelor's degree in:
• Glass & Ceramics
• Chemical Engineering
• Mechanical Engineering
• Production Engineering
• Relevant technical discipline.

Preferred

• Degree/Diploma in Glass Technology or Ceramics.
• Six Sigma / Quality Management certification.
• Training in 8D, FMEA, SPC, MSA and CAPA.

22. Experience

• 12–18 years of relevant experience in manufacturing quality, preferably in the glass container manufacturing industry.
• Strong preference for candidates with experience in:
• Container glass manufacturing
• IS machine operations
• Hot-end and cold-end quality
• Electronic inspection systems
• Glass laboratory

Preferred Industry Experience

Candidates from glass container manufacturers or organizations supplying glass containers to major FMCG, pharmaceutical, food & beverage, liquor, cosmetics or other packaging customers would be preferred.

The candidate should have strong knowledge of:

• Glass container manufacturing process
• IS machine process
• Annealing process
• Hot-end and cold-end inspection
• Dimensional measurement
• Electronic inspection
• Statistical Process Control
• 8D
• CAPA
• FMEA
• MSA
• Quality Control Plans
• ISO 9001/QMS
• Customer specifications
• Calibration systems
• Quality data analysis.
• Strong analytical and problem-solving ability.
• Strong leadership and team-management skills.
• Customer-oriented approach.
• Ability to work under production pressure without compromising quality.
• Strong communication and presentation skills.
• Ability to work cross-functionally.
• Decision-making capability.
• Ownership and accountability.
• Ability to challenge incorrect processes and drive corrective action.
• Strong follow-up and execution capability.

25. Ideal Candidate Profile

The ideal candidate should be a hands-on Quality professional with strong glass container manufacturing experience, capable of independently managing the complete Quality function from raw material → batch → furnace → forming → annealing → cold-end inspection → packing → dispatch → customer complaint.

The candidate should not be limited to laboratory or inspection activities. He/she should have demonstrated experience in process quality improvement, customer handling, complaint resolution, quality system management and cross-functional problem solving.

Priority should be given to candidates who have:

• Direct glass container manufacturing experience.
• Experience with external customers.
• Experience in customer audits.
• Experience handling customer complaints independently.
• Strong knowledge of hot-end and cold-end defects.
• Experience with electronic inspection systems.
• Proven record of reducing rejection and customer complaints.
• Experience in new product development and customer approval.
• Strong leadership capability to manage the Quality team and influence Production/Engineering teams.

Reporting & Working Relationship

Reports to: AGM – Operations / Plant Head

Key Internal Interfaces:

Production | Furnace | Batch House | Maintenance | Instrumentation | Electrical | Engineering | Packing | Stores | Purchase | Sales | HR

Key External Interfaces:

Customers | Customer Quality Teams | Suppliers | Auditors | Certification Agencies | Testing Laboratories

Overall Objective

To ensure that every glass container dispatched from the plant consistently meets customer specifications and statutory/internal quality requirements, while continuously reducing defects, customer complaints, rejection and quality-related manufacturing losses.