Assistant Manager - Quality Control (QC)

Department

Quality Control / Quality Assurance

Experience

Minimum 7 Years relevant experience in Quality Control / Inspection in a Pressure Vessel, Heat Exchanger, Air Fin Cooler or Heavy Engineering Fabrication manufacturing company.

Educational Qualification

• B.E. / B.Tech. in Mechanical Engineering
• Additional qualifications/certifications in Quality, Welding or Inspection will be an advantage.

Required Experience & Exposure

The candidate should have strong hands-on experience in:

• Quality Control activities in Pressure Vessel / Heat Exchanger / Air Fin Cooler manufacturing
• Heavy engineering and fabrication activities
• Inspection of fabricated equipment and components
• ASME Code requirements and standards
• Welding inspection and quality control
• Preparation and review of quality documentation
• Stage-wise inspection and final inspection
• Coordination with Third Party Inspection (TPI) agencies and customers
• Experience in Oil & Gas / Refinery / Petrochemical projects will be an added advantage.

Key Responsibilities

Quality Control & Inspection

• Plan and supervise day-to-day QC inspection activities for manufacturing and fabrication.
• Monitor quality at various stages of fabrication, including:

1. Incoming material inspection
2. Material identification and traceability
3. Fit-up inspection
4. Welding inspection
5. Dimensional inspection
6. NDT coordination and review
7. Hydro / pneumatic testing, wherever applicable
8. Final inspection
9. Painting/coating inspection
10. Packing and dispatch inspection

• Ensure products are manufactured as per approved drawings, specifications, codes and customer requirements.

Welding & Fabrication Quality

• Monitor welding and fabrication activities and ensure compliance with approved WPS/PQR/WPQ.
• Review welding parameters, consumable control and welder qualifications.
• Ensure proper identification and traceability of welding consumables and materials.
• Coordinate with Welding Engineers / Production team for resolution of welding-related quality issues.
• Monitor weld repairs and ensure proper documentation and re-inspection.

ASME & Code Compliance

• Working knowledge of relevant ASME Codes, particularly:

1. ASME Section VIII
2. ASME Section IX
3. ASME Section V
4. Other applicable ASME requirements

• Ensure fabrication and inspection activities comply with applicable codes, specifications and approved procedures.
• Review inspection requirements specified in customer specifications and project documents.

Documentation

• Review and maintain Quality Control documentation, including:

1. Inspection & Test Plans (ITP)
2. Quality Control Plans
3. Inspection Reports
4. Material Test Certificates (MTC)
5. WPS/PQR/WPQ records
6. NDT reports
7. Dimensional inspection reports
8. Hydro/Pneumatic test reports
9. Calibration records
10. Final inspection reports
11. Manufacturing Record Books / Quality Dossiers

• Ensure proper documentation and traceability throughout the manufacturing process.

Customer & TPI Coordination

• Coordinate with customers, consultants and Third Party Inspection agencies for stage inspections.
• Attend customer/TPI inspection calls and resolve inspection observations.
• Ensure timely closure of inspection comments, NCRs and punch points.
• Support preparation for customer audits and inspections.

NCR & Corrective Actions

• Identify quality issues and initiate NCRs wherever required.
• Coordinate with Production, Welding, Design and other departments for root-cause analysis.
• Ensure implementation and closure of corrective and preventive actions.
• Monitor recurring quality issues and take preventive measures.

Team Management

• Supervise and guide QC Inspectors and junior QC personnel.
• Allocate inspection activities and monitor their performance.
• Train QC personnel on inspection procedures, drawings, specifications and applicable codes.
• Ensure effective coordination between QC, Production, Planning, Welding and Engineering departments.

Quality Improvement

• Identify opportunities for reducing rework, rejection and fabrication defects.
• Monitor quality performance and prepare periodic quality reports.
• Implement improvements in inspection procedures and manufacturing quality.
• Ensure compliance with the company's Quality Management System / IMS requirements.

Technical Skills Required

The candidate should have good knowledge of:

• Pressure Vessel / Heat Exchanger fabrication
• Air Fin Cooler manufacturing and inspection
• Welding processes and inspection
• WPS / PQR / WPQ
• ASME Section VIII & Section IX
• NDT methods and reports
• Dimensional inspection
• Material identification and traceability
• MTC review
• Hydrostatic / Pneumatic testing
• ITP preparation and implementation
• Customer and TPI inspection
• NCR / Root Cause Analysis / Corrective Action
• Quality documentation and dossier preparation
• Engineering drawings and specifications
• Measuring instruments and calibration

Preferred Experience

Experience in any of the following will be an added advantage:

• Oil Refineries
• Oil & Gas industry
• Petrochemical projects
• EPC projects
• Heat Exchanger / Air Fin Cooler manufacturing
• Pressure Vessel manufacturing
• ASME-certified manufacturing facilities
• Experience dealing with reputed TPI agencies and refinery customers.

Key Competencies

• Strong technical knowledge of fabrication and inspection
• Good understanding of ASME Codes
• Strong problem-solving and analytical skills
• Ability to interpret engineering drawings
• Good communication and coordination skills
• Ability to independently handle customer/TPI inspections
• Team leadership and people-management skills
• Strong documentation and reporting skills
• Ability to work under project deadlines

Reporting

Reports To: Quality Head / General Manager Quality