QA/QC Senior Engineer cum Manager

Industry: Heavy Fabrication (ISO Dry Bulk Containers, Tank Containers, Pressure Vessels)

Department: Quality Assurance & Quality Control (QA/QC)

Reports To: Plant Head / General Manager / Director

Location: Manufacturing Plant

Position Summary The QA/QC Senior Engineer cum Manager is responsible for establishing, implementing, monitoring, and continuously improving the Quality Management System (QMS) across the organization. The role ensures that ISO Dry Bulk Containers, Tank Containers, Pressure Vessels, and fabricated products are manufactured in compliance with customer specifications, international codes, statutory requirements, and company quality standards.

The incumbent shall lead quality planning, inspection, testing, documentation, audits, customer inspections, third-party inspections, supplier quality, and continuous improvement activities while ensuring zero customer complaints and high product reliability.

Key Responsibilities

1. Quality Management System (QMS)

- Maintain and improve the ISO 9001 Quality Management System.
- Ensure compliance with documented procedures and work instructions.
- Prepare, review, and revise SOPs, Quality Plans, Inspection Procedures, and Quality Manuals.
- Conduct Management Review Meetings (MRM).
- Ensure CAPA implementation and effectiveness.
- Monitor Quality KPIs and prepare monthly reports.

2. Code & Standard Compliance

Ensure compliance with

- ASME Section VIII Div.1 & Div.2
- ASME Section IX
- ISO 11120
- ISO 1496
- CSC Requirements
- ADR/RID
- IMDG Code
- EN Standards
- PED
- IBR (where applicable)
- AWS
- ASTM
- ISO Welding Standards
- Customer Specifications

3. Incoming Material Quality Control

- Verify Material Test Certificates (MTC).
- Conduct Raw Material Inspection.
- Heat Number Traceability.
- PMI (Positive Material Identification).
- Material Identification & Color Coding.
- Maintain Material Traceability Register.
- Vendor Inspection Reports.
- Incoming NCR generation.

4. Welding Quality Control Responsible for complete welding quality system including:

- WPS Preparation
- PQR Qualification
- WPQ Qualification
- Welder Performance Monitoring
- Welding Parameter Verification
- Welding Consumable Control
- Electrode Baking Records
- Gas Monitoring
- Welding Repair Control
- Repair Percentage Analysis
- Weld Mapping
- Joint Traceability

5. Fit-up Inspection

- Dimensional Verification
- Alignment Inspection
- Root Gap Inspection
- Bevel Angle Verification
- Joint Preparation
- Assembly Inspection
- Fit-up Release

6. In-Process Inspection

- Stage Inspection
- Visual Inspection
- Dimensional Inspection
- Process Verification
- Welding Sequence Monitoring
- Quality Hold Points
- Customer Hold Points

7. NDT Coordination

Coordinate and monitor

- Radiography Testing (RT)
- Ultrasonic Testing (UT)
- Magnetic Particle Testing (MT)
- Dye Penetrant Testing (PT)
- Vacuum Box Test
- Helium Leak Test
- Pneumatic Test
- Hydro Test
- Air Leak Test

Ensure acceptance criteria as per applicable code. 8.



Hydro Test & Pneumatic Test

- Test Pressure Verification
- Test Gauge Calibration
- Pressure Holding Time
- Safety Precautions
- Leakage Verification
- Test Documentation
- Final Approval

9. Final Inspection

Responsible for

- Visual Inspection
- Dimensional Inspection
- Functional Inspection
- Marking Verification
- Name Plate Verification
- Painting Verification
- Sticker Verification
- Documentation Review
- Dispatch Clearance

10. Pressure Vessel Quality Control

- Shell Inspection
- Head Inspection
- Nozzle Orientation
- Reinforcement Pad Inspection
- Internal Inspection
- External Inspection
- Joint Efficiency Verification
- Stress Relieving Records
- PWHT Verification
- Pressure Test Witness

11. Tank Container Quality

- ISO Dimension Verification
- Corner Fitting Inspection
- Frame Alignment
- Twist Lock Dimension
- Barrel Inspection
- Ladder Inspection
- Walkway Inspection
- Safety Valve Verification
- Bottom Outlet Inspection
- Valve Box Inspection

12. Dry Bulk Container Quality

- Hopper Inspection
- Cone Angle Verification
- Aeration System Inspection
- Discharge System Inspection
- Butterfly Valve Inspection
- Pipeline Inspection
- Structural Verification
- Leak Test

13. Painting Quality

Monitor

- Surface Preparation
- Blast Profile
- DFT Measurement
- WFT Measurement
- Holiday Test
- Adhesion Test
- Paint Batch Control
- Paint Consumption Analysis
- Environmental Monitoring

14. Calibration Control

Responsible for

- Measuring Instruments
- Vernier
- Micrometer
- Pressure Gauges
- Torque Wrench
- DFT Gauge
- Temperature Indicator
- Weighing Scale
- Welding Machines Calibration Records

15. Third Party Inspection (TPI)

Coordinate inspections with

- Lloyd's Register
- BV
- DNV
- TUV
- SGS
- IRS
- ABS
- Customer Inspectors

Prepare inspection documents and obtain approvals. 16. Documentation Control

Maintain complete records including

- ITP
- QAP
- MTC
- NDT Reports
- Hydro Reports
- Calibration Certificates
- WPS
- PQR
- WPQ
- Inspection Reports
- Final Dossiers
- MDR (Manufacturing Data Record)

17. Customer Complaint Handling

- Root Cause Analysis
- 8D Report
- CAPA
- Corrective Action
- Preventive Action
- Customer Communication
- Complaint Trend Analysis

Target:
- Zero Repeat Complaint

18. Internal & External Audits

Conduct

- Internal Audit
- Process Audit
- Product Audit
- Supplier Audit
- Layered Process Audit

Coordinate external audits from certification bodies and customers. 19. Supplier Quality Management

- Vendor Qualification
- Vendor Audit
- Vendor Rating
- Supplier CAPA
- Incoming Quality Monitoring
- Vendor Development

20. Team Management





Lead and develop

- QA Engineers
- QC Engineers
- QC Inspectors
- NDT Coordinators
- Documentation Engineers
- Weld Inspectors

Responsibilities include manpower planning, training, performance evaluation, and discipline. 21. Continuous Improvement

Drive improvement initiatives through

- Lean Manufacturing
- Six Sigma Concepts
- Kaizen
- Poka-Yoke
- Quality Cost Reduction
- Rework Reduction
- Scrap Reduction
- Productivity Improvement

22. Daily Responsibilities

- Daily Quality Meeting
- Shop Floor Inspection
- NCR Review
- Rework Monitoring
- Customer Inspection Planning
- Daily Production Quality Review
- Quality Dashboard Update
- Daily Management Report (DMR)

23. Monthly KPI

Responsible for monitoring

- Right First Time (RFT)
- First Pass Yield (FPY)
- NCR Count
- Rework %
- Rejection %
- Customer Complaints
- Vendor Rejection %
- On-Time Inspection
- Audit Score
- Calibration Compliance
- CAPA Closure
- Cost of Poor Quality (COPQ)
- Dispatch Quality Index

Required Qualification

- B.E./B.Tech in Mechanical Engineering (Preferred)
- Diploma Mechanical Engineering (Minimum for 15 YEARS experienced candidates)
- ASNT Level-II Certification (Preferred)
- CSWIP 3.1/3.2 or Equivalent (Preferred)
- Lead Auditor ISO 9001 (Preferred)

Experience

- 10–15+ years in Heavy Fabrication.
- Minimum 5 years in a managerial QA/QC role.
- Experience in ISO Tank Containers, Dry Bulk Containers, Pressure Vessels, and ASME Code fabrication.
- Robust exposure to TPI inspections and international customer requirements.

Required Skills

- Strong leadership and decision-making.
- Expertise in fabrication drawings and GD&T.;
- Knowledge of welding processes (GMAW, GTAW, SMAW, SAW).
- Familiarity with ERP/MRP systems and MS Office.
- Excellent communication in English.
- Analytical problem-solving and root cause analysis.
- Team building and mentoring.
- Time management and planning.

Key Performance Indicators (KPIs)

- 100% Code & Customer Specification Compliance.
- Zero Critical Quality Escapes.
- Zero Major NCR from Customers.
- Zero Dispatch Without QA Release.
- Hydro Test First-Time Pass Rate 98%.
- RT/NDT Acceptance Rate 98%.
- Rework 2%.
- Scrap 1%.
- Customer Complaint 0.5%.
- CAPA Closure Within Target Time.
- Calibration Compliance: 100%.
- Audit Compliance Score 95%.
- On-Time Documentation Submission: 100%.
- On-Time Inspection Clearance: 100%.
- Team Training Compliance: 100%.

Accountability The QA/QC Senior Engineer cum Manager is fully accountable for ensuring that every ISO Dry Bulk Container, Tank Container, and Pressure Vessel manufactured by the company complies with applicable international codes, statutory regulations, customer specifications, and internal quality standards before dispatch. The role is responsible for preventing quality failures, reducing rework and scrap, ensuring complete documentation, achieving customer satisfaction, and driving a culture of continuous quality improvement across the organization.

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