The Quality Assurance Manager is responsible for leading the entire Quality function within a fasteners manufacturing environment. This role is pivotal in establishing a "Zero Defect" culture by ensuring rigorous product quality analysis, implementing continuous improvement initiatives, and maintaining stringent compliance with international standards. The incumbent will drive customer satisfaction by integrating advanced statistical tools, failure analysis, and process control to optimize manufacturing excellence across machining, heat treatment, and surface finishing operations.
Main duties/responsibilities
o Lead the Quality Function: Oversee the entire quality department, managing a team of engineers and inspectors to ensure all fasteners (bolts, nuts, screws, and special parts) meet dimensional and mechanical specifications.
o Strategic Planning: Develop and execute the Quality roadmap, aligning quality objectives with business goals to reduce Cost of Poor Quality (COPQ).
o Product Analysis: Monitor product quality metrics to identify trends, deviations, and areas of risk.
o Continuous Improvement: Lead cross-functional teams in implementing Lean, Six Sigma, and Kaizen projects to enhance process capability and reduce scrap.
o Root Cause Analysis: Investigate internal and external quality failures and implement permanent corrective actions.
o Testing Protocols: Oversee the physical and metallurgical laboratory, ensuring rigorous testing of fasteners including tensile, hardness, torque, and salt spray tests.
o Quality Validation: Validate new product introduction (NPI) and process changes through First Article Inspection (FAI) and PPAP (Production Part Approval Process).
o Plating & Heat Treatment: Specifically, ensure that Zinc Plating, Nickel Plating, and Heat Treatment processes are validated to avoid hydrogen embrittlement and ensure corrosion resistance.
o SPC Implementation: Implement and monitor SPC charts (X-bar, R-charts, P-charts) for critical parameters within the forging, threading, and heat treatment processes to ensure statistical control.
o Capability Studies: Conduct Cp/Cpk studies to ensure machinery and processes are capable of meeting customer tolerances.
o FMEA Facilitation: Lead Design and Process FMEA (D/PFMEA) sessions to proactively identify potential failure modes in the fastening process.
o Risk Mitigation: Utilize RPN (Risk Priority Number) analysis to prioritize improvement actions and prevent defects before they occur.
o Internal Audits: Conduct and manage Internal Audits (Process & System) to ensure adherence to IATF 16949 / ISO 9001 standards.
o Compliance: Ensure strict compliance with customer-specific requirements and regulatory standards.
o Vendor Quality: Drive Supplier Quality Assurance (SQA) to ensure incoming raw materials meet specifications.
o Customer Interaction: Act as the primary point of contact for customer quality concerns, handling 8D reports and corrective action requests.
o Field Feedback: Analyze customer complaints and warranty returns to drive systemic improvements.
KPI:s of the role
o Internal PPM (Parts Per Million
o Customer PPM / Rejections
o Scrap Reduction
o First Pass Yield (FPY)
o Customer Scorecards / Customer Satisfaction Level (CSL)
Experience and knowledge required for the role
o Education: B.E. / B.Tech in Mechanical Engineering (Master's degree preferred).
o Experience: 10 - 15 years of progressive experience in Quality Assurance/Management.
o Industry: Essential - Experience in the Fasteners Manufacturing Industry or heavy metal forming/automotive components.
o Deep understanding of SPC, MSA, and Process Capability.
o Hands-on experience with FMEA, Control Plans, and APQP.
o Knowledge of Heat Treatment (case hardening, through hardening) to ensure structural integrity.
o In-depth knowledge of Zinc Plating & Nickel Plating processes (corrosion resistance, thickness testing, and adhesion).
o Understanding of metallurgy and mechanical properties of steel fasteners.
o Strong leadership and team mentoring skills.
o Excellent analytical and problem-solving abilities (8D, 5Why, Ishikawa).
o High attention to detail and a proactive approach to risk management.
o Internal Auditor (Certified for ISO 9001:2015 / IATF 16949).
Six Sigma Green Belt/Black Belt is a distinct advantage.
Pay: ₹100,000.00 - ₹300,000.00 per month
Benefits:
- Cell phone reimbursement
- Health insurance
- Internet reimbursement
- Life insurance
- Paid sick time
- Provident Fund
Work Location: In person
