Key Responsibilities A. Forming / Hot-End Quality

Monitor and control the quality parameters of the container forming process, including:

Gob weight and gob temperature

Section-wise process parameters

Blank and blow mould conditions

Neck finish dimensions

Body dimensions

Wall thickness

Weight distribution

Finish quality

Verticality

Deflection

Thermal shock-related issues

Cracks and checks

Mould-related defects

Forming process stability.

Work closely with Production, Maintenance and Hot-End teams to identify and eliminate recurring defects.

B. Annealing / Lehr Quality

Monitor annealing process parameters.

Ensure correct lehr temperature profile and process conditions.

Monitor residual stress and annealing quality.

Investigate breakage and thermal-stress-related defects.

Coordinate with Production and Maintenance for corrective actions.

4. Cold-End Quality & Inspection

Lead the cold-end quality function and ensure effective inspection of finished glass containers.

Critical quality parameters include:

Container weight

Height

Diameter

Neck/finish dimensions

Capacity

Wall thickness

Base thickness

Verticality

Finish quality

Heel/base defects

Body defects

Cracks/checks

Stones

Seeds/blisters

Cord

Black spots

Bubbles

Deformation

Coating quality

Surface defects.

Ensure proper functioning and calibration of inspection equipment such as:

Electronic inspection machines

Vision inspection systems

Dimensional inspection equipment

Weight checkers

Pressure testers

Thermal shock testers

Coating inspection equipment

Laboratory instruments.

5. Product Inspection & Release

Establish inspection plans and sampling standards for all products.

Ensure final product inspection before dispatch.

Maintain product quality records and traceability.

Authorize product release/rejection based on approved specifications.

Control non-conforming products through proper identification, segregation and disposition.

Ensure proper control of rejected and downgraded products.

Monitor quality performance line-wise, machine-wise, section-wise and product-wise.

6. Customer Quality & Complaint Management

This is a key responsibility of the position.

- Act as the primary Quality contact for customers.
- Understand customer specifications and quality expectations.
- Review customer complaints and coordinate investigation.

~ Conduct structured root-cause analysis using:

- 5 Why
- Fishbone Analysis
- 8D

~ CAPA.

- Provide timely corrective and preventive action reports to customers.
- Monitor effectiveness of corrective actions.
- Participate in customer visits, audits, trials and technical discussions.
- Support new customer/product development.
- Coordinate product approval and qualification with customers.
- Maintain customer-specific quality standards and specifications.
- Track customer complaints, rejection, returns and quality claims.

Preference should be given to candidates having direct experience in dealing with external customers, customer audits and customer complaint resolution.

7. Quality Management System

Establish, implement and maintain the plant Quality Management System.

Ensure compliance with applicable ISO and customer requirements.

Prepare and maintain:

SOPs

Work instructions

Quality plans

Inspection standards

Control plans

Check sheets

Quality records.

Conduct internal quality audits.

Ensure closure of audit observations.

Monitor CAPA effectiveness.

Drive continuous improvement in the Quality Management System.

8. Quality Data Analysis & Improvement

Develop and monitor quality KPIs such as:

Internal rejection %

Customer rejection %

Customer complaints

Defects per million / PPM where applicable

Line-wise rejection

Machine-wise rejection

Section-wise rejection

Critical defect percentage

Quality losses

Downgraded production

Glass defects

Dimensional defects

Packing defects.

Use statistical and analytical tools to identify trends and recurring problems.

Prepare daily, weekly and monthly quality performance reports for management.

9. Root Cause Analysis & Continuous Improvement

Lead cross-functional quality improvement teams.

Identify chronic and recurring defects.

Drive systematic root-cause analysis.

Implement permanent corrective actions rather than temporary containment.

Reduce internal rejection and customer complaints.

Identify opportunities for:

Process improvement

Material optimization

Defect reduction





Yield improvement

Cost reduction.

Participate in improvement projects such as Kaizen, Six Sigma or other structured improvement initiatives.

10. Laboratory Management

Manage the plant quality laboratory and ensure:

Proper testing procedures.

Calibration of laboratory equipment.

Testing of raw materials and finished products.

Glass chemical analysis.

Physical and dimensional testing.

Stress/annealing tests.

Thermal shock tests.

Pressure tests where applicable.

Proper maintenance of laboratory records.

Availability of testing facilities and consumables.

11. Calibration & Measurement System

Establish calibration schedules for all measuring and testing equipment.

Ensure calibration through approved agencies.

Maintain calibration records.

Ensure traceability of measurement standards.

Identify and control equipment found outside calibration limits.

Conduct measurement system verification wherever required.

12. Packing & Dispatch Quality

Ensure packing quality meets customer requirements.

Monitor:

Pallet quality

Carton quality

Dividers/separators

Shrink wrapping

Strapping

Labeling

Product identification

Lot traceability.

Ensure proper segregation and identification of rejected/non-conforming products.

Coordinate with Packing, Stores and Dispatch teams to prevent quality issues reaching customers.

13. Supplier Quality Management

Evaluate and monitor critical material suppliers.

Review supplier quality performance.

Coordinate supplier corrective actions.

Participate in supplier audits where required.

Establish supplier quality improvement plans.

Monitor incoming rejection and supplier-related quality losses.

14. New Product Development & Trials

Review customer drawings/specifications.

Establish quality requirements for new products.

Support mould trials and production trials.

Develop inspection standards for recent products.

Validate dimensions and functional requirements.

Prepare product quality documentation for customer approval.

Support commercialization of new products.

15. Customer / External Audit Management

Lead preparation and coordination for:

Customer audits

ISO audits

Certification audits

Statutory/third-party inspections

Supplier/customer technical audits.

Ensure timely closure of audit observations and maintain proper evidence of compliance.

16. Team Management

Lead and develop the Quality team.

Define responsibilities and accountability for Quality Engineers, Inspectors and Laboratory personnel.

Prepare manpower and shift requirements.

Conduct training and competency development.

Evaluate team performance.

Establish strong ownership for quality at each manufacturing stage.

Develop second-line Quality leadership.

Ensure effective shift-wise quality monitoring.

17. Cross-Functional Responsibilities

The Quality Manager shall work closely with:

Production

Furnace & Batch House

Maintenance

Instrumentation

Electrical

Engineering

Packing

Stores

Purchase

Sales

Customer Service

HR

Management.

The role requires the ability to influence production and other functional teams without compromising quality standards .

18. Quality & Cost Improvement

The Quality Manager shall actively contribute to reduction of:

Internal rejection

Customer rejection

Glass wastage

Downgraded production

Quality-related production losses

Customer complaints

Rework

Packing-related losses.

Quality improvement should be driven with a focus on both customer satisfaction and manufacturing cost reduction .

19. Authority

The Quality Manager shall have authority to:

Stop/hold dispatch of products not meeting specifications.

Reject non-conforming materials.

Place non-conforming products under quality hold.

Recommend rejection/rework/downgrade decisions.

Escalate critical quality issues to Plant Management.

Initiate corrective and preventive actions.

Recommend process changes to improve product quality.

Participate in customer technical discussions.

Approve routine quality inspection and testing procedures within the approved QMS.





20. Key Performance Indicators – KPI

Performance shall be evaluated based on:

- Customer complaint reduction.
- Customer rejection reduction.
- Internal rejection reduction.
- Quality loss reduction.
- Critical defect reduction.
- Product conformity.
- Customer audit performance.
- Timely closure of CAPA/8D.
- Supplier quality improvement.
- Laboratory and calibration compliance.
- Quality system compliance.
- New product approval and successful trials.
- Reduction of recurring quality problems.
- Team competency development.
- Contribution to overall plant yield and productivity.

21. Qualification

Essential

Bachelor's degree in:

Glass & Ceramics

Chemical Engineering

Mechanical Engineering

Production Engineering

Industrial Engineering

Relevant technical discipline.

Preferred

Degree/Diploma in Glass Technology or Ceramics.

ISO/QMS Lead Auditor qualification.

Six Sigma / Quality Management certification.

Training in 8D, FMEA, SPC, MSA and CAPA.

22. Experience

- 12–18 years of relevant experience in manufacturing quality, preferably in the glass container manufacturing industry .
- Strong preference for candidates with experience in:
- Container glass manufacturing
- IS machine operations
- Hot-end and cold-end quality
- Electronic inspection systems
- Glass laboratory
- Customer complaint handling
- Customer audits
- New product development.

Preferred Industry Experience

Candidates from glass container manufacturers or organizations supplying glass containers to major FMCG, pharmaceutical, food & beverage, liquor, cosmetics or other packaging customers would be preferred.

23. Technical Competencies

The candidate should have strong knowledge of:

- Glass container manufacturing process
- Furnace/melting process
- IS machine process
- Forming defects
- Annealing process
- Hot-end and cold-end inspection
- Dimensional measurement
- Electronic inspection
- Statistical Process Control
- Root Cause Analysis
- 8D

~ CAPA

~ FMEA

~ MSA

~ Quality Control Plans

~ ISO 9001/QMS

- Customer specifications
- Calibration systems
- Quality data analysis.

24. Behavioural Competencies

Strong analytical and problem-solving ability.

Strong leadership and team-management skills.

Customer-oriented approach.

Ability to work under production pressure without compromising quality.

Strong communication and presentation skills.

Ability to work cross-functionally.

Decision-making capability.

Ownership and accountability.

Data-driven approach.

Ability to challenge incorrect processes and drive corrective action.

Strong follow-up and execution capability.

25. Ideal Candidate Profile

The ideal candidate should be a hands-on Quality professional with strong glass container manufacturing experience , capable of independently managing the complete Quality function from raw material → batch → furnace → forming → annealing → cold-end inspection → packing → dispatch → customer complaint .

The candidate should not be limited to laboratory or inspection activities. He/she should have demonstrated experience in process quality improvement, customer handling, complaint resolution, quality system management and cross-functional problem solving .

Priority should be given to candidates who have:

Direct glass container manufacturing experience.

Experience with external customers.

Experience in customer audits.

Experience handling customer complaints independently.

Strong knowledge of hot-end and cold-end defects.

Experience with electronic inspection systems.

Proven record of reducing rejection and customer complaints.

Experience in new product development and customer approval.

Strong leadership capability to manage the Quality team and influence Production/Engineering teams.

Reporting & Working Relationship

Reports to: AGM – Operations / Plant Head

Key Internal Interfaces:

Production | Furnace | Batch House | Maintenance | Instrumentation | Electrical | Engineering | Packing | Stores | Purchase | Sales | HR

Key External Interfaces:

Customers | Customer Quality Teams | Suppliers | Auditors | Certification Agencies | Testing Laboratories

Overall Objective

'To ensure that every glass container dispatched from the plant consistently meets customer specifications and statutory/internal quality requirements, while continuously reducing defects, customer complaints, rejection and quality-related manufacturing losses.'

📌 QA / Quality Manager (Pulivendula)
🏢 Samyu Glass
📍 Pulivendula