In-Process Quality Inspector / In-Process Quality Control EngineerDepartment
Quality
Industry
Automotive Wiring Harness Manufacturing
Reporting To
Quality Head / Management Representative / Plant Head
Job Location
Factory / Manufacturing Unit
Job Purpose
To ensure that all wiring harness manufacturing processes are carried out as per approved drawings, specifications, control plans, work instructions and customer requirements. The candidate will be responsible for monitoring in-process quality, preventing defects, controlling rejection and rework, supporting root-cause analysis and developing quality awareness among operators and production staff.
Key Responsibilities
- Carry out in-process inspection at different stages of wiring harness production.
- Verify wire cutting length, wire size, colour, strip length and insulation condition as per drawing or specification.
- Check crimping quality including crimp height, crimp width, terminal position, pull force and conductor condition.
- Ensure correct terminals, connectors, seals, sleeves, tapes, tubes, clips and other components are being used.
- Inspect terminal insertion, connector locking, secondary locking and cavity position.
- Verify routing, branching, taping, tubing and harness dimensions as per approved drawing or sample.
- Check continuity, short circuit, open circuit and electrical test results wherever applicable.
- Ensure first-piece inspection and approval before regular production starts.
- Conduct patrol inspection and random inspection during production.
- Identify defects at the earliest stage and stop defective material from moving to the next process.
- Segregate non-conforming products and ensure proper identification and disposition.
- Maintain in-process inspection records, rejection records, rework records and check sheets.
- Monitor internal rejection, rework and defect trends on a daily basis.
- Support Quality Head in root-cause analysis and corrective and preventive actions.
- Participate in customer complaint investigation and internal problem-solving activities.
- Verify process parameters against control plans, process sheets and work instructions.
- Ensure operators are following approved work instructions and quality standards.
- Train and guide operators regarding common defects, workmanship standards and quality requirements.
- Conduct line clearance checks during product or model changeover.
- Ensure traceability requirements are followed wherever applicable.
- Verify calibration status of gauges, testers and measuring instruments used on the production floor.
- Support PPAP, APQP, FMEA, Control Plan and customer-specific requirement activities as required.
- Participate in internal audits, process audits, product audits and customer audits.
- Ensure 5S, cleanliness and proper material identification at quality inspection and production areas.
- Coordinate with Production, Stores, Maintenance and Quality departments for immediate resolution of quality issues.
- Escalate repeated or serious quality problems immediately to the Quality Head and Production Head.
- Work towards reduction in rejection, rework, customer complaints and process variation.
Key Quality Checks
The candidate should be able to check and understand:
- Wire size and wire colour
- Cutting length
- Stripping length
- Terminal crimping
- Crimp height
- Pull-force test
- Terminal damage
- Wire strand damage
- Connector cavity position
- Terminal locking
- Secondary lock
- Seal position
- Taping and tubing
- Branch length
- Harness dimensions
- Continuity testing
- Short/open circuit
- Wrong component
- Missing component
- Wrong routing
- Identification and traceability
- Workmanship defects
Qualification
For Quality Inspector:
ITI / Diploma in Electrical, Electronics, Mechanical, Automobile or relevant technical field.
For Quality Control Engineer:
Diploma / B.Tech / B.E. in Electrical, Electronics, Mechanical, Automobile or related engineering discipline.
Experience
Preferred experience: 1–4 years in automotive wiring harness manufacturing or automotive component manufacturing.
Fresh Diploma candidates with good technical understanding may also be considered for junior positions.
Technical Knowledge Required
Candidate should preferably have knowledge of:
- Wiring harness manufacturing process
- Crimping process and crimping defects
- Pull-force testing
- Continuity testing
- Basic measuring instruments
- Vernier caliper
- Micrometer
- Crimp height micrometer
- Control Plan
- Work Instructions
- Inspection Standards
- Basic FMEA
- Basic SPC
- Basic MSA
- 7 QC Tools
- Root Cause Analysis
- 5 Why Analysis
- Poka-Yoke
- ISO 9001
- Basic IATF 16949 requirements
Skills Required
- Strong observation skills
- Good attention to detail
- Ability to identify defects quickly
- Basic problem-solving ability
- Good communication with operators and supervisors
- Ability to maintain records properly
- Discipline and responsibility
- Ability to work on the shop floor
- Ability to handle production pressure without compromising quality
- Good follow-up skills
Behavioural Expectations
The candidate should:
- Be honest and responsible
- Be disciplined and punctual
- Take ownership of quality problems
- Be willing to learn
- Be firm but respectful with operators
- Work as a team with Production and Quality
- Be proactive instead of waiting for complaints
- Focus on prevention rather than only inspection
Key Performance Indicators – KPI
Performance may be evaluated on:
- Internal rejection percentage
- Rework percentage
- Defects detected at in-process stage
- Customer complaints related to process defects
- First-pass yield
- First-piece approval compliance
- Inspection record completion
- Corrective action closure
- Repeated defect reduction
- 5S compliance
- Operator quality awareness
- Audit findings related to production quality
Authority
The In-Process Quality Inspector / Engineer should have authority to:
- Hold suspected or defective material
- Stop production in case of serious quality risk
- Reject non-conforming material as per company procedure
- Request segregation and re-inspection
- Escalate repeated process violations
- Request corrective action from Production
- Release production after satisfactory verification as per defined procedure
Preferred Candidate Profile
The ideal candidate should have practical shop-floor knowledge, good understanding of automotive wiring harness defects and the confidence to interact with operators and production supervisors.
The person should not behave only as an inspector who checks finished output. The objective of the role is to prevent defects during the process, improve operator discipline, support production and continuously reduce rejection and rework.
Pay: ₹20,000.00 - ₹25,000.00 per month
Work Location: In person
