Responsibilities:
- Develop and implement quality plans for shaped refractory products for raw materials, processing, firing, and finished goods.
- Oversee end-to-end refractory brick manufacturing: crushing, grinding, batching, mixing, shaping (pressing/extrusion), drying, firing, and finishing.
- Monitor incoming raw material quality and ensure conformance to chemical, physical, and mineralogical specifications
- Ensure traceability, documentation and compliance with ISO 9001, IMS, and customer-specific quality requirements.
- Define CTQs, control plans, inspection plans, SOPs, and testing protocols for shaped products.
- Drive standardization of quality practices across shifts and product lines.
- Conduct supplier audits and periodic performance reviews.
- Lead RM qualification, alternate source development, and cost-optimization initiatives without compromising quality.
- Ensure effective control of defects such as cracks, laminations, warpage, under/overfiring, dimensional deviations, and strength variation.
- Ensure testing of shaped refractories as per IS/ASTM/ISO standards: AP/BD, CCS, PLC, HMOR, refractoriness, RUL, thermal shock, creep, etc.
- Approve final product release and COA issuance.
- Control rejection rates and drive reduction through root cause analysis and corrective actions.
- Ensuring timely evaluation and qualification of new raw materials through lab trials and industrial validation.
- Supervising calibration, maintenance, and validation of laboratory equipment to ensure reliability of results.
- Conducting testing and analysis of R&D samples, pilot batches, and customer trial samples.
- Reduction in quality complaints of products through root cause analysis and corrective/preventive actions.
- Handle customer complaints related to shaped products and lead failure analysis (RCA, CAPA).
- Customization of products / cost savings exercises for products
- Coordinating with cross-functional teams (production, procurement, R&D, Sales, site teams) to resolve quality issues of raw materials and finished products
- Training and mentoring QA/QC teams to upgrade technical knowledge and ensure skill development.
- Conducting vendor audits, quality evaluation, and qualification of raw material suppliers.
- Supporting new product development with performance validation and scale-up trials
- Promote sustainability initiatives such as reclaim material utilization without performance loss
- Support Sales with technical justifications, datasheets, and benchmarking against competitors.
Proven leadership in team handling, mentoring, and capability building
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Profile and Competencies:
Education, background, level of experience
- B.Tech/ M.Tech (Ceramic Technology/Enginering) from a reputed Ceramic Institute.
- Minimum 12 years' experience in a QA & QC role of a reputed Refractory industry. Experience in Refractory Shaped products (brick industry) is preferred. The incumbent should have -
- Knowledge in Ceramics and Refractories
- Sound knowledge of refractory brick manufacturing processes, including raw material evaluation and selection, control of critical process parameters, and final product testing and inspection.
- Strong understanding of refractory brick chemistry, mineralogy, and thermomechanical behavior.
- Hands-on experience with shaped refractory manufacturing and kiln operations.
- Ability to interpret test data and link it to process behavior.
- Ensure consistent product quality through strict adherence to SOPs and control plans.
- Analytical and problem-solving skills
- Excellent written and oral communication
- Knowledge of refractory property – performance correlation.
- Hands on experience in various testing and characterization methods pertaining to refractories.
- Knowledge of quality standards (ISO, BIS, ASTM, DIN, EN) and certification processes.
- Familiarity with lean manufacturing, Six Sigma, Kaizens, and TQM principles.
- Strong cross functional collaboration, customer-oriented mindset with focus on performance, reliability, and cost-effectiveness.
