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QPC Head, BRW

Calderys -
Bhubaneswar, Orissa

Apply Now

Job details

Full-time

Qualifications

Six Sigma Certification
ISO 9001
Master's degree
Six Sigma
Programmable logic controllers
Bachelor's degree
Quality control
QA/QC
Manufacturing
Leadership
Lean Six Sigma Certification
Lean manufacturing

Full job description

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.

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.

Apply Now

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