Quality Control (QC) Engineer MOV Manufacturing

Company: Thakor Electrocomp

Department: Quality Control

Job Location: Andheri, Mumbai, Maharashtra

Experience: 2-5 Years

1. Job Purpose To ensure the quality, reliability and consistency of Metal Oxide Varistors (MOVs) manufactured at Thakor Electrocomp by implementing effective quality control systems, inspection procedures and testing methodologies.

The role involves monitoring product quality from incoming raw materials to finished goods, conducting electrical and reliability testing, controlling critical manufacturing parameters, identifying non-conformities and implementing corrective and preventive actions.

The QC Engineer will work closely with Production, Engineering and R&D; teams to maintain product quality, improve manufacturing processes and ensure compliance with applicable international standards, customer specifications and the company's quality management system.

2. Key Responsibilities

A. Incoming Quality Control (IQC)

- Perform incoming inspection of raw materials and components, including MOV ceramic discs, lead wires, epoxy materials, insulating materials and packaging materials.
- Verify material specifications, dimensions, physical appearance and supplier test certificates.
- Conduct electrical inspection of incoming MOV ceramic discs, including Varistor Voltage (V1mA), wherever applicable.
- Establish and maintain incoming material inspection criteria and acceptance standards.
- Identify, segregate and report non-conforming materials.
- Maintain supplier quality records and coordinate with procurement and suppliers for quality-related issues.

B. In-Process Quality Control (IPQC)

- Understand the complete MOV manufacturing process and establish appropriate quality checkpoints at critical manufacturing stages.
- Monitor critical product and process parameters in accordance with approved production flow charts, SOPs and control plans.
- Perform dimensional, visual, electrical and mechanical inspections during manufacturing.
- Monitor critical quality parameters such as disc dimensions, lead alignment, welding quality, epoxy coating thickness and curing conditions.
- Identify process variations and take immediate action to prevent defective products from moving to subsequent stages.
- Coordinate with Production and Engineering teams to resolve process-related quality issues.
- Maintain in-process inspection records and quality monitoring reports.

C. Final Quality Control (FQC) & Electrical Testing

- Conduct final inspection and electrical testing of finished MOV products.
- Verify product characteristics against approved datasheets, specifications and customer requirements.
- Perform and monitor the following electrical tests:
- Varistor Voltage (V1mA).
- Leakage Current.
- Clamping Voltage.
- Maximum AC Voltage (VAC).
- Maximum DC Voltage (VDC).
- Capacitance, wherever applicable.
- Other electrical parameters as per product specifications.
- Ensure proper functioning and accuracy of electrical testing equipment.
- Verify dimensional accuracy, lead length, lead spacing, epoxy coating, marking and overall product appearance.
- Ensure compliance with approved product specifications before batch release.
- Prepare and maintain final inspection and test reports.

D. Surge Testing & Reliability Validation

- Understand and operate MOV surge testing equipment.
- Conduct surge current and endurance testing as per approved test procedures and applicable standards.
- Understand 8/20 s current waveform and associated surge testing parameters.
- Analyse surge test results, including peak current, peak voltage, residual voltage and energy.
- Monitor changes in Varistor Voltage and Leakage Current before and after surge testing.
- Conduct or coordinate thermal stability, high-temperature, mechanical strength, lead pull, vibration and environmental tests, wherever applicable.




- Evaluate product performance against approved reliability and qualification requirements.
- Prepare detailed test reports and highlight deviations or abnormal observations.

E. Quality Control Tools & Process Improvement

- Apply appropriate quality control tools for monitoring, analysing and improving product quality.

- Maintain and implement
- 7 QC Tools.
- Statistical Process Control (SPC).
- Failure Mode and Effects Analysis (FMEA).
- 5 Why Analysis.
- Fishbone / Ishikawa Diagram.
- Root Cause Analysis (RCA).
- 8D Problem Solving.
- Corrective and Preventive Action (CAPA).
- AQL Sampling and Inspection Plans.
- Measurement System Analysis (MSA) and Gauge R&R.;
- Process Capability Analysis (Cp / Cpk).
- Monitor rejection trends, process variations and recurring defects.
- Recommend corrective measures to improve product quality and manufacturing efficiency.
- Support continuous improvement activities through defect reduction, Kaizen and 5S initiatives.

F. Failure Analysis & Customer Complaint Management

- Investigate internal rejections, product failures and customer complaints.
- Conduct root cause analysis and identify corrective and preventive measures.
- Analyse electrical, mechanical and environmental failure modes.
- Investigate quality issues related to welding defects, excessive leakage current, incorrect Varistor Voltage, epoxy coating variation, curing defects and surge test failures.
- Prepare technical failure analysis and CAPA reports.
- Coordinate with Production, Engineering, R&D; and suppliers for effective problem resolution.
- Monitor the effectiveness of corrective actions and ensure prevention of recurring failures.

G. Quality Documentation & ISO Compliance

- Prepare and maintain quality-related documentation, including:
- Incoming Quality Inspection (IQC) Reports.
- In-Process Quality Inspection (IPQC) Reports.
- Final Quality Inspection (FQC) Reports.
- Electrical and Surge Test Reports.
- Reliability and Qualification Test Reports.
- Non-Conformance Reports (NCR).
- Corrective and Preventive Action (CAPA) Reports.
- Calibration Records.
- Inspection Checklists and SOPs.
- Control Plans and FMEA Documents.
- First Article Inspection (FAI) Reports.
- Maintain proper batch identification and product traceability from incoming raw materials to finished goods.
- Ensure inspection equipment is calibrated and calibration records are maintained.
- Support implementation and maintenance of ISO 9001:2015 Quality Management System requirements.
- Participate in internal audits, external audits, customer audits and certification audits.
- Ensure timely closure of audit observations and non-conformities.

H. Team Coordination & Training

- Coordinate with Production, Engineering, R&D;, Stores and Procurement teams on quality-related matters.
- Train production operators and inspectors on inspection methods, quality standards and approved SOPs.
- Ensure quality requirements are followed at all critical manufacturing stages.
- Support new product development, product qualification and process validation activities.
- Promote quality awareness and a zero-defect mindset across the manufacturing team.

3. Education & Experience

Educational Qualification:

- Bachelor's Degree or Diploma in Electrical, Electronics or Mechanical Engineering.
- Candidates with relevant qualifications in electronics or materials engineering will also be considered.

Work Experience:

- 25 years of experience in Quality Control or Quality Assurance.




- Experience in electronic component manufacturing, preferably MOV, varistor, resistor, capacitor or other passive electronic components.
- Fresh engineering graduates with strong technical knowledge may be considered for QC Trainee positions.

4. Technical Knowledge & Competencies The candidate should possess working knowledge of the following: MOV & Electrical Testing Knowledge

- Understanding of Metal Oxide Varistors and their electrical characteristics.
- Varistor Voltage, Leakage Current and Clamping Voltage.
- MOV surge current and energy withstand characteristics.
- Surge testing equipment and 8/20 s waveform.
- Electrical and reliability testing procedures.

Quality Control & Engineering Tools

- 7 QC Tools, SPC and FMEA.
- RCA, 5 Why, Fishbone and 8D methodology.
- CAPA and NCR management.
- AQL sampling and inspection methodologies.
- MSA, Gauge R&R; and Cp/Cpk.
- Calibration and measurement system management.

Testing Instruments & Equipment

- Digital Multimeter.
- LCR Meter.
- High Voltage Tester.
- MOV Varistor Voltage Testing Equipment.
- Leakage Current Testing Equipment.
- Surge Generator / Surge Testing Equipment.
- Vernier Caliper and Micrometer.
- Measuring microscope and other dimensional inspection instruments.

Standards & Quality Systems

- ISO 9001:2015.
- IEC 61051 series Varistors.
- IEC 61000-4-5 Surge Immunity Testing, where applicable to the test application.
- IEC 61643 series Surge Protective Devices, where applicable.
- Customer-specific quality and testing requirements.

5. Key Performance Indicators (KPIs)

Performance Parameter

Expected Objective

Incoming Quality

Reduction in raw material rejection

In-Process Quality

Reduction in process defects and rejection

Final Product Quality

Improved first-pass yield

Electrical Testing

100% compliance with approved specifications

Reliability Testing

Compliance with approved qualification criteria

Customer Complaints

Timely investigation and resolution

CAPA Management

Effective root cause identification and closure

Documentation

Accuracy and timely completion of quality records

Process Improvement

Reduction in rejection, rework and recurring defects

Calibration Management

100% compliance with calibration schedules

Audit Compliance

Timely closure of audit observations

6. Required Skills & Personal Attributes

- Strong analytical and problem-solving abilities.
- Good understanding of electrical and electronic components.
- Hands-on approach towards inspection and testing activities.
- Excellent observation and attention to detail.
- Ability to interpret technical datasheets and test specifications.
- Good documentation and report-writing skills.
- Effective communication and coordination abilities.
- Ability to independently identify and report quality issues.
- Willingness to work on the manufacturing floor and coordinate with production teams.
- Robust ownership, accountability and commitment to product quality.

7. Preferred Candidate Profile Candidates having hands-on experience in MOV / Varistor manufacturing or passive electronic component industries will be preferred.

The ideal candidate should have practical knowledge of electrical testing, surge testing, reliability validation, quality control tools, process monitoring and failure analysis.

The candidate should be capable of independently managing routine quality inspection activities, analysing test results, identifying manufacturing defects, maintaining quality documentation and coordinating with cross-functional teams to ensure consistent product quality.

8. Quality Objective THAKOR ELECTROCOMP To manufacture reliable, consistent and high-quality Metal Oxide Varistors through systematic quality control, robust process monitoring, accurate electrical testing, effective failure analysis and continuous improvement.

Quality is everyone's responsibility.

📌 Quality Control Manager (Mumbai)
🏢 Thakor Electrocomp
📍 Mumbai