Role Purpose: Own in-process quality for medium and power transformers (33–400 kV), ensuring products meet applicable standards, customer specifications, and Ayr Energy's Quality Management System (QMS). Lead stage-wise quality controls across core, coil, tanking, assembly, oil processing, and final tests to achieve first-time-right builds, reduce rework, and elevate customer satisfaction.

Key Responsibilities
1. Quality System & Documentation
• Create and maintain Control Plans, Inspection & Test Plans (ITP), stage checklists, work instructions, and traveler/route cards; enforce hold/witness points.
• Own NCR/CAPA—facilitate structured root cause analysis (5-Why, Fishbone), implement fixes, and verify effectiveness; drive defect prevention.
• Maintain device history records, test certificates, as-built dossiers, and customer documentation packs for shipment and FAT. 2. Supplier & Customer Interface
• Qualify and develop suppliers for critical items (CRGO, copper, bushings, OLTC, radiators, tanks); conduct audits and PPAP/FAI where applicable.
• Lead customer stage and final inspections (FAT), coordinate third-party inspections/test labs, and close observations promptly. 3. Data, Metrics & Continuous Improvement
• Track FPY, rework/repair hours, supplier PPM, test bay failures, and COPQ; publish weekly/monthly dashboards.
• Apply 7 QC tools, MSA (GR&R;), process capability (Cp/Cpk/Pp/Ppk), and SPC to stabilize and improve processes.
• Run kaizens to reduce defects (e.g., oil leaks, winding shorts, paint defects) and cycle time at critical stages. Compliance & Standards
• ISO 9001:2015 QMS; ISO 14001 and ISO 45001 (EHS) – adhere to procedures and participate in audits. Qualifications &

Experience:
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Education:
BE/B.




Tech or Diploma in Electrical/Mechanical Engineering (Electrical preferred).
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Experience:
8–15 years in transformer manufacturing quality; at least 5 years hands-on in-process/stage inspection and test bay exposure for 66 kV+ class.
• Certifications (preferred): Six Sigma Green Belt/Black Belt, ASQ CQA/CQE, NDT Level II (VT/PT), Lead Auditor (ISO 9001). Skills & Competencies:
• Strong knowledge of transformer construction, drawings (GA, core/coil, schematic), tolerances, and insulation systems.
• Proficiency with electrical tests (TTR, WR, IR/PI, tan δ/PF, SFRA, AC withstand) and interpretation of results.
• Hands-on with metrology and torque tools; ability to set up gauges/fixtures and verify special processes.
• QMS documentation, RCA/CAPA, statistical analysis (MSA, Cp/Cpk), and SPC; working knowledge of ERP/MES and Minitab/Excel.
• Clear written/verbal communication; ability to coach operators, manage audits, and interface with customers and TPI bodies. Key Performance Indicators (KPIs):
• First-pass yield at critical stages and final test
• Supplier PPM and on-time NCR closure
• Defect/rework reduction (%), COPQ trend
• Calibration compliance and audit scores
• On-time documentation pack readiness and shipment clearance Why Join Ayr Energy: Be part of a quick-growing grid hardware company building mission-critical products. You will shape world-class manufacturing systems, work with global suppliers and utilities, and grow into leadership roles with clear impact on reliability and safety of power networks. Work

Conditions:
• Primarily shop-floor based role with regular presence in test bay and oil processing areas.
• Shift and weekend support during critical builds or customer inspections as needed.
• Travel up to 60% for supplier audits, customer FATs, or type test witnessing.

📌 Copy of Lead, QA (Hyderabad)
🏢 Ayr Energy
📍 Hyderabad