– QUALITY MANAGER

Designation: Quality Manager

Department: Quality Assurance / Quality Control

Location: Mysore, Karnataka

Reporting To: General Manager / Operations Head / Plant Head

Industry: Automotive Plastic Injection Moulding

Nature of Business: Manufacturing of critical insert-moulded plastic components for automobile applications, including Starter & Alternator parts

Experience: 8–15 years preferred in Automotive / Plastic Injection Moulding / Auto Component Industry

Qualification: B.E./B.Tech/Diploma in Mechanical / Polymer / Plastics / Production / Industrial Engineering or equivalent

Preferred Knowledge: IATF 16949, ISO 9001, APQP, PPAP, FMEA, MSA, SPC, 8D, CAPA, Control Plan, Process Audit and Customer Quality Requirements

1. JOB PURPOSE

The Quality Manager is responsible for establishing, maintaining and continuously improving the company's complete quality management system and ensuring that 100% of supplied products meet customer specifications, drawings, standards and agreed quality requirements. The position carries overall responsibility for:

- Incoming quality
- In-process quality
- Final inspection
- Pre-dispatch quality
- Customer complaints
- Supplier quality
- Process capability
- Quality documentation
- Corrective and preventive actions
- Internal and process audits
- IATF-related compliance
- Quality improvement
- Rejection reduction
- Customer satisfaction
- Quality team performance

The Quality Manager must ensure that no defective, doubtful or non-conforming material is knowingly released to the customer. For critical automobile components, particular importance must be given to visual defects, dimensional accuracy, insert positioning, moulding defects, functional requirements and traceability, because quality failures can result in customer rejection, production-line disruption and serious downstream consequences.

1. KEY RESPONSIBILITIESA. OVERALL QUALITY MANAGEMENT

- Take complete ownership of the quality function of the factory.
- Establish and maintain effective quality standards for all manufacturing processes.
- Ensure that quality requirements are clearly understood and followed by Production, Stores, Maintenance, Tool Room, Purchase and other departments.
- Define quality objectives and monitor achievement against targets.
- Establish systems to achieve:
- 100% good quality
- Minimum customer complaints
- Minimum internal rejection
- Minimum rework
- Zero dispatch of non-conforming material
- Effective traceability
- Compliance with customer requirements
- Ensure effective implementation of documented procedures, work instructions, inspection standards and quality records.
- Review quality performance on a daily, weekly and monthly basis.
- Identify recurring quality problems and implement permanent corrective action rather than temporary containment.

1. INCOMING QUALITY CONTROL

The Quality Manager shall ensure that all incoming materials are controlled before being released for production.

Responsibilities include

- Establish incoming inspection standards for raw materials, bought-out components, inserts, packaging materials and other critical items.
- Ensure inspection as per specifications, drawings, standards and approved samples.
- Verify material certificates wherever required.
- Ensure proper identification and segregation of:
- Accepted material
- Rejected material
- Hold material
- Pending inspection material
- Monitor supplier quality performance.
- Coordinate with Purchase and Stores for supplier-related quality issues.
- Ensure proper records for incoming inspection.




- Prevent unapproved or non-conforming material from entering production.

1. IN-PROCESS QUALITY CONTROL

The Quality Manager shall ensure that quality is built into the process rather than detected only at final inspection.

Responsibilities include

- Establish inspection frequency and inspection methods.
- Ensure first-piece / first-off approval after:
- Machine setup
- Mould change
- Material change
- Process parameter change
- Insert change
- Tool maintenance
- Verify critical process parameters.
- Ensure production operators follow approved work instructions and inspection standards.
- Monitor injection moulding parameters affecting product quality.
- Ensure effective control of:
- Short moulding
- Flash
- Sink marks
- Weld lines
- Burn marks
- Flow marks
- Black spots
- Colour variation
- Warpage
- Cracks
- Voids
- Dimensional deviations
- Insert misalignment
- Insert damage
- Missing inserts
- Contamination
- Burrs and sharp edges
- Assembly-related defects
- Ensure suitable control of critical-to-quality characteristics.

1. VISUAL QUALITY CONTROL

Since the company manufactures critical automobile components, the Quality Manager must establish strong visual inspection discipline.

Responsibilities include

- Develop approved visual standards and defect samples.
- Define acceptable and unacceptable visual limits.
- Train inspectors and operators on visual defects.
- Ensure adequate lighting and proper inspection conditions.
- Establish defect photographs / visual standards at inspection stations.
- Ensure inspectors understand customer-specific appearance requirements.
- Prevent subjective inspection decisions by establishing clear acceptance criteria.
- Periodically validate inspectors' understanding and inspection effectiveness.
- Conduct layered verification of visual inspection activities.

1. FINAL INSPECTION & PRE-DISPATCH QUALITY

The Quality Manager shall ensure that only fully conforming products are dispatched.

Responsibilities include

- Establish final inspection procedures.
- Ensure inspection against:
- Drawing
- Customer specification
- Approved sample
- Control Plan
- Work instruction
- Packaging standard
- Ensure correct quantity verification.
- Ensure proper identification and traceability.
- Verify batch / lot information wherever applicable.
- Ensure rejected, reworked and approved materials are clearly segregated.
- Verify all required inspection reports before dispatch.
- Implement release authority for final product.
- Ensure no material is dispatched without required quality clearance.

1. CUSTOMER COMPLAINT MANAGEMENT

The Quality Manager shall take complete ownership of customer complaints.

Responsibilities include

- Immediately communicate customer complaints to relevant departments.
- Establish containment action without delay.
- Identify affected lots, production periods, machines and batches.
- Stop further dispatch wherever necessary.
- Investigate the actual root cause.
- Use structured problem-solving methods such as:
- 5 Why
- Fishbone Analysis
- 8D
- Pareto Analysis
- Why-Why Analysis
- Implement permanent corrective actions.
- Verify effectiveness of corrective actions.




- Prepare professional customer response reports.
- Maintain complete complaint history.
- Monitor recurring complaints and ensure they are not repeated.
- Conduct lessons-learned activities across similar products and processes.

1. CUSTOMER QUALITY REQUIREMENTS

The Quality Manager shall ensure complete understanding and implementation of customer-specific requirements.

This includes

- Customer specifications
- Customer quality standards
- Special characteristics
- Packaging requirements
- Traceability requirements
- Inspection requirements
- PPAP requirements
- Change-management requirements
- Customer portals / reporting requirements
- Customer audit requirements

The Quality Manager shall ensure that changes in customer requirements are communicated to all concerned departments and incorporated into relevant documents and processes.
1. APQP / PPAP RESPONSIBILITIES

For current products, development projects and process changes, the Quality Manager shall coordinate and ensure appropriate quality planning.

Responsibilities include

- APQP coordination
- Process Flow Diagram
- PFMEA
- Control Plan
- Work Instructions
- Inspection Standards
- MSA requirements
- Capability studies
- PPAP documentation
- Sample inspection
- Dimensional reports
- Material reports
- Performance test reports
- Process validation
- Run-at-Rate support
- Customer submission and approval

No new product or significant process change should be released without required quality evaluation and approval.
1. PFMEA & CONTROL PLAN MANAGEMENT

The Quality Manager shall ensure that PFMEA and Control Plans remain active working documents rather than merely audit documents.

Responsibilities include

- Lead PFMEA reviews.
- Ensure process risks are properly identified.
- Link identified risks with corresponding controls.
- Ensure special characteristics are identified.
- Update PFMEA after:
- Customer complaints
- Internal rejection
- Process failures
- Engineering changes
- Tool changes
- New risks
- Ensure Control Plans reflect actual shop-floor conditions.
- Verify that operators are working according to the latest approved documents.

1. SPC & PROCESS CAPABILITY

The Quality Manager shall establish effective statistical monitoring for critical characteristics.

Responsibilities include

- Identify critical and special characteristics.
- Establish SPC requirements.
- Monitor process capability.
- Review Cp / Cpk where applicable.
- Identify process trends before defects occur.
- Conduct capability studies.
- Ensure corrective action where process capability is inadequate.
- Train quality and production personnel on basic statistical concepts.

1. MSA / GAUGE CONTROL

The Quality Manager shall ensure reliability of inspection and measurement systems.

Responsibilities include

- Establish gauge calibration systems.
- Ensure all measuring instruments are identified and traceable.
- Prevent use of expired / overdue calibration instruments.
- Coordinate external calibration where required.
- Conduct Gauge R&R; / MSA studies where applicable.
- Maintain calibration records.
- Ensure proper handling and storage of measuring instruments.
- Evaluate suitability of inspection equipment for critical dimensions.

1. INTERNAL QUALITY AUDITS

The Quality Manager shall plan and conduct internal audits.

This includes

- System audits
- Process audits
- Product audits
- Layered process audits
- 5S / discipline

Pay: ₹22,000.00 - ₹40,000.00 per month

Benefits

- Health insurance

Work Location: In person

📌 Quality Assurance Engineer (Mysuru)
🏢 Engineering Plastics, Mysore
📍 Mysuru