Quality Department Manager- Transformer

Job Description:

Designation: Quality Department Manager
Department: Quality Assurance & Quality Control
Reporting To: Plant Head / Head – Quality
Location: Chittoor, Andhra Pradesh
Transformer Capacity Range: Up to 20 MVA (Power & Distribution Transformers)
Qualification: B.Tech (Electrical / Mechanical Engineering)
Experience: 15 Years (Transformer / Heavy Electrical Equipment Manufacturing)

JOB PURPOSE
Own the plant's overall Quality Management System, covering incoming material inspection, in-process quality control across all manufacturing sections, final inspection, customer complaint resolution, and maintenance of quality certifications (ISO 9001 and related standards).

PROJECT PHASE RESPONSIBILITIES

• Prepare Inspection & Test Plans (ITPs) and quality control plans for new transformer orders/designs.
• Conduct First Article Inspection (FAI) / PPAP-equivalent approval for new designs before regular production release.
• Coordinate customer and third-party quality audits for new projects and certifications.
• Support Design/R&D with quality-related design-for-manufacturability inputs on new products.

PRODUCTION PHASE RESPONSIBILITIES

• Oversee incoming material inspection for CRGO steel, copper/aluminium conductors, insulation materials, and transformer oil.
• Manage in-process quality control checkpoints across Core, Winding, Assembly, Processing/Drying, Tanking, and Testing sections.
• Conduct final inspection and quality clearance before dispatch, ensuring compliance with customer specifications and standards.
• Manage Non-Conformance Reports (NCRs) and Corrective and Preventive Actions (CAPA) across the plant.
• Investigate and resolve customer quality complaints, driving root-cause analysis and containment actions.
• Maintain and continually improve the ISO 9001 (and related ISO 14001/45001) quality management system, including internal audits.

TECHNICAL SKILLS

• Strong knowledge of quality tools — SPC, 8D problem solving, root-cause analysis (5-Why, Fishbone), FMEA.
• Understanding of transformer manufacturing quality standards — IS 2026, IEC 60076, and customer-specific QAPs.
• Familiarity with metrology, calibration management, and measurement systems analysis.
• Working knowledge of ISO 9001 QMS requirements and internal/external audit processes.

LEADERSHIP REQUIREMENTS

• Lead a team of QA/QC engineers and inspectors deployed across all manufacturing sections.
• Build a cross-functional quality culture in partnership with all section managers.
• Coordinate with customers, third-party inspection agencies (TPIA), and certification bodies.
• Drive quality training programs for shop-floor staff and new-hire onboarding on quality standards.

KEY PERFORMANCE INDICATORS (KPIs)

• Customer complaint rate (PPM or per order).
• In-house rejection/rework rate (%) by section.
• On-time quality clearance for dispatch (%).
• Number and severity of audit non-conformances (internal/external).
• Cost of Poor Quality (COPQ) as % of production cost.
• CAPA closure rate within defined timelines (%).

SAFETY & COMPLIANCE RESPONSIBILITIES

• Ensure quality lab safety practices, including safe handling of test samples and chemicals (e.g., oil testing).
• Maintain calibration compliance and safe use of measurement/test instruments.
• Ensure proper documentation and compliance with ISO 9001/14001/45001 requirements.
• Support safety-related inspection sign-offs (e.g., insulation integrity, pressure/leak tests) before dispatch.
• Promote a quality-and-safety-integrated mindset across all sections through joint audits.
• Ensure statutory and customer-mandated safety-related test compliance is documented and traceable.