Job Title: Quality Manager
Department: Quality Assurance
Reports To: Plant Head
Location: Kukas, Jaipur
Education: B.Tech Mechanical
Experience: 5 to 8 Years
Salary: 50K to 70K
Overview:
The Quality Manager is responsible for developing and implementing quality management systems to ensure that all products meet customer and regulatory requirements. This role will oversee all quality-related activities within the plant, including inspections, audits, compliance with standards, and continuous improvement initiatives. The Quality Manager works closely with other departments such as production, design, and procurement to ensure that quality standards are maintained throughout the bus body building process.
Key Responsibilities:
• Develop, implement, and maintain quality management systems to meet ISO and industry-specific standards for bus body manufacturing.
• Ensure all bus bodies meet internal and external quality requirements, including customer expectations and compliance with government regulations.
• Lead a team of quality inspectors and technicians, ensuring they are well-trained and equipped to carry out inspections and tests.
• Establish and maintain quality inspection standards, methods, and procedures for incoming materials, in-process products, and finished buses.
• Conduct regular audits of suppliers, production processes, and finished products to ensure consistent quality.
• Analyze data from inspections and audits, identify trends or issues, and implement corrective and preventive actions (CAPA).
• Collaborate with design, production, and procurement teams to solve quality issues and implement design or process changes to improve product quality.
• Ensure that all employees involved in the production process are aware of the quality standards and receive regular training.
• Lead the investigation of customer complaints and warranty issues, determine root causes, and implement corrective actions.
• Manage non-conformance reports (NCRs) and ensure timely resolution of quality issues.
• Foster a culture of continuous improvement, driving initiatives that improve product quality, reduce waste, and increase efficiency.
• Ensure compliance with safety standards in all quality-related processes.
• Prepare and present quality reports to senior management, highlighting performance trends and areas for improvement.
Key Result Areas (KRAs):
1. Quality Control:
• Maintain high levels of quality control through inspections, audits, and product testing at various stages of production. • Ensure adherence to industry standards and customer specifications.
2. Regulatory Compliance:
• Ensure compliance with all relevant national and international quality standards (such as ISO, BIS, etc.) and government regulations (such as ARAI, CMVR, etc.).
3. Supplier Quality Management:
• Implement a robust system for incoming material inspections and supplier audits to maintain the quality of raw materials and components.
4. Customer Satisfaction:
• Address and resolve customer complaints and warranty issues by implementing corrective actions.
5. Continuous Improvement:
• Drive quality improvement initiatives and contribute to cost reduction and efficiency improvements within the plant.
6. Team Leadership & Development:
• Lead the quality team effectively, ensuring continuous training and skill development for quality inspectors and technicians.
7. Corrective and Preventive Action (CAPA):
• Implement corrective actions for any identified defects and ensure preventive measures to avoid recurrence.
8. Reporting & Documentation:
• Maintain accurate and timely documentation of all quality activities, reports, and audits for internal and external reviews.
Key Performance Indicators (KPIs):
1. Product Quality:
• % of rejected products (internal/external): Measure the percentage of products rejected either internally during inspections or externally by customers.
• First-pass yield (FPY): Percentage of buses that pass all quality checks the first time without rework. • % of rework: Track the percentage of production that requires rework due to quality issues.
2. Customer Satisfaction:
• Customer complaint resolution time: Measure the time taken to resolve customer complaints and warranty issues.
• % reduction in customer complaints: Track the reduction in complaints year over year.
• Customer satisfaction score: Gather feedback from customers regarding product quality through surveys or feedback forms.
3. Regulatory Compliance:
• % compliance with quality standards: Ensure all buses meet required quality standards without deviation.
• Number of regulatory violations or non-conformances: Track any deviations from national or international standards during audits or inspections.
4. Supplier Quality:
• % of supplier parts/materials rejected: Measure the rejection rate of materials and components from suppliers during incoming inspections.
• Supplier defect rate: Monitor the number of defects caused by supplier parts.
• Supplier audit score: Regularly audit suppliers and assign scores based on their adherence to quality standards.
5. Process Efficiency:
• Average time for corrective actions (CAPA): Measure the time taken to implement corrective and preventive actions following quality issues.
• percentage reduction in process defects: Track and reduce defects during the production process through continuous improvement initiatives.
• Non-conformance reports (NCRs) closed on time: Ensure that all NCRs are resolved within the prescribed time frame.
6. Cost of Quality:
• Cost of poor quality (COPQ): Measure costs incurred due to defects, rework, customer returns, or warranty claims.
• Cost of inspection and testing as a % of production cost: Monitor the cost spent on quality inspections and testing compared to the overall production cost.
7. Continuous Improvement:
• Number of quality improvement projects implemented annually: Track the number of improvement initiatives led by the quality department.
• % improvement in key quality metrics (FPY, defect rate, etc.): Measure overall improvement in quality performance.
8. Team Development:
• Employee skill improvement index: Track the number of training sessions conducted and the skill improvement of the quality team.
• Employee engagement score: Measure engagement and satisfaction levels of the quality team to ensure effective leadership and motivation.
9. Audit Performance:
• Audit pass rate: Track the percentage of internal and external audits passed without major non-conformances.
• % of audit findings closed on time: Ensure that all findings from audits are addressed and closed in a timely manner.
Qualifications and Skills:
• Bachelor’s degree in Mechanical Engineering, Quality Management, or a related field.
• Minimum of 3-5 years of experience in quality management, preferably in the automotive or bus manufacturing industry.
• Strong knowledge of quality standards (ISO 9001, ISO/TS 16949, etc.) and regulatory requirements for bus body manufacturing.
• Experience with quality management systems (QMS) and tools such as Six Sigma, FMEA, CAPA, and Root Cause Analysis (RCA).
• Excellent leadership and team management skills with a focus on employee development.
• Strong analytical and problem-solving abilities.
• Proficient in using quality management software and reporting tools.
• Attention to detail and the ability to work under pressure in a fast-paced manufacturing environment.
