1. Powder Coating Quality Management
- Develop and implement quality standards for powder coating operations.
- Ensure coated products meet customer specifications for appearance, thickness, adhesion, durability, and corrosion resistance.
- Monitor powder coating processes to maintain consistent product quality.
- Approve first-off samples before production.
2. Incoming Material Inspection
- Verify the quality of incoming metal substrates, pretreatment chemicals, and powder coating materials.
- Inspect surface preparation prior to coating.
- Ensure raw materials comply with approved specifications.
3. Process Quality Control
- Monitor pretreatment processes including:
- Degreasing
- Cleaning
- Phosphating/Chromating (where applicable)
- Drying
- Verify coating parameters such as:
- Gun voltage/current settings
- Air pressure
- Powder flow rate
- Booth cleanliness
- Conveyor speed
- Oven curing temperature and time
4. Powder Coating Inspection and Testing
- Conduct routine quality inspections and laboratory testing, including:
- Dry Film Thickness (DFT)
- Cross Hatch Adhesion Test
- Impact Resistance Test
- Bend/Flexibility Test
- Gloss Measurement
- Colour Matching (RAL standards)
- Visual Surface Inspection
- Orange Peel Evaluation
- Pinholes, Craters, Runs, and Contamination Checks
- Curing Verification (MEK Rub Test)
- Salt Spray Test
- Humidity Resistance Test
- Hardness Test (Pencil Hardness)
5. Quality Documentation
- Maintain inspection reports, quality records, and test reports.
- Prepare Certificates of Conformance (COC) where applicable.
- Ensure traceability of production batches.
- Maintain calibration records for inspection instruments.
6. Non-Conformance Management
- Investigate coating defects such as:
- Poor adhesion
- Under curing
- Over curing
- Uneven coating
- Colour variation
- Blistering
- Rust formation
- Surface contamination
- Perform root cause analysis using 5 Why, Fishbone Diagram, or similar methodologies.
- Implement corrective and preventive actions (CAPA).
7. Customer Complaint Management
- Handle customer complaints related to coating quality.
- Coordinate corrective actions with production and maintenance teams.
- Prepare customer response reports and improvement plans.
8. Process Improvement
- Analyze quality trends and defect data.
- Reduce rejection, rework, and coating defects.
- Improve first-pass yield and coating efficiency.
- Support Lean Manufacturing, Six Sigma, Kaizen, and 5S initiatives.
9. Compliance and Audits
- Ensure compliance with:
- ISO 9001 Quality Management System
- Customer quality requirements
- Internal quality procedures
- Environmental and safety regulations
- Support internal, customer, and certification audits.
10. Equipment Calibration
- Ensure periodic calibration of:
- Coating Thickness Gauges
- Gloss Meters
- Cure Test Equipment
- Adhesion Test Kits
- Temperature Recorders
- Oven Calibration Instruments
11. Team Leadership
- Supervise Quality Inspectors and QA/QC Engineers.
- Train operators on powder coating quality standards.
- Conduct regular quality awareness programs.
- Evaluate team performance and identify training needs.
12. Cross-Functional Coordination
- Work closely with:
- Production
- Maintenance
- Engineering
- Procurement
- Customer Service
- Sales
- Ensure quality requirements are met throughout the manufacturing process.
Required Qualifications
- Bachelor's degree or Diploma in Mechanical Engineering, Metallurgical Engineering, Industrial Engineering, Materials Engineering, or a related field.
- 5–10 years of experience in powder coating quality checking, preferably in the metal packaging, sheet metal fabrication or engineering industry.
- Experience with ISO 9001 quality systems and powder coating inspection techniques.
Technical Skills
- Powder coating process knowledge
- Metal surface preparation
- Pretreatment chemistry
- Coating thickness measurement
- Adhesion and durability testing
- Corrosion testing
- Quality management systems (ISO 9001)
- Root cause analysis (5 Why, Fishbone, 8D)
- SPC (Statistical Process Control)
- FMEA and Control Plans
- CAPA implementation
- ERP systems and Microsoft Excel
- Internal auditing techniques
Key Performance Indicators (KPIs)
- First-pass acceptance rate
- Powder coating defect rate
- Customer complaint rate
- Internal rejection rate
- Rework percentage
- Coating thickness compliance
- Adhesion test pass rate
- Salt spray test pass rate
- On-time closure of CAPA
- Audit compliance score
- Cost of poor quality (COPQ)
- Overall equipment quality performance
- Customer satisfaction score
Job primary working location will be in Aurangabad, Maharastra location, Based on requirement should be ready to work in Udupi location on flexible basis.
Pay: ₹30,000.00 - ₹60,000.00 per month
Benefits:
Work Location: In person
