Quality Head – Sheet Metal Fabrication

Quality Head – Sheet Metal Fabrication

Job Location:Mysore

Department:Quality Assurance / Quality Control (QA/QC)

Reporting To:Plant Head / Operations Head / General Manager

Job Summary:

The Quality Head is responsible for defining, implementing, and monitoring the quality management system (QMS) in sheet metal fabrication processes to ensure that all products meet customer specifications and industry standards. This role involves leading the quality assurance, quality control, and continuous improvement initiatives while ensuring compliance with ISO 9001, IATF 16949, and other regulatory standards.

Key Responsibilities:

1. Quality Management System (QMS) & Compliance

• Establish, maintain, and improve the Quality Management System (QMS) in line with ISO 9001, IATF 16949, AS 9100, or customer-specific requirements.
• Ensure compliance with regulatory and customer standards for Turret Punching, Press Brake, Welding, Powder Coating, Phosphating, Tapping, and PEM Insertion.
• Drive internal audits, supplier audits, and third-party audits to ensure adherence to quality protocols.

2. Quality Control & Assurance

• Define and enforce incoming, in-process, and final inspection procedures.
• Oversee the use of measuring instruments (CMM, Vernier Calipers, Micrometers, Height Gauges, Profile Projectors, etc.).
• Ensure First Article Inspection (FAI), PPAP, SPC (Statistical Process Control), and MSA (Measurement System Analysis) are effectively implemented.

3. Defect Reduction & Root Cause Analysis

• Drive root cause analysis (RCA) and corrective and preventive actions (CAPA) for customer complaints and internal defects.
• Implement 5 Whys, Fishbone Diagram, and Pareto Analysis to identify and eliminate recurring quality issues.
• Lead Failure Mode and Effects Analysis (FMEA) to assess and mitigate process risks.

4. Supplier & Customer Quality Management

• Develop and monitor supplier quality performance (Incoming Quality Control – IQC).
• Work with the procurement team to qualify and improve supplier processes.
• Address customer complaints (NCRs – Non-Conformance Reports) and ensure timely resolution with corrective actions.

5. Continuous Improvement & Lean Manufacturing

• Implement Lean Manufacturing, Six Sigma, and Kaizen techniques to improve quality and efficiency.
• Reduce rejection rates, rework costs, and scrap percentages through process improvements.
• Drive 5S, Poka-Yoke (Error Proofing), and Zero Defect initiatives across production lines.

6. Team Leadership & Training

• Lead and mentor the QA/QC team, including engineers, inspectors, and auditors.
• Conduct training programs on quality standards, problem-solving methodologies, and best practices.
• Foster a culture of quality awareness and continuous improvement among employees.

7. Reporting & Documentation

• Prepare and present weekly/monthly quality reports on defect trends, supplier performance, and process improvements.
• Maintain records for ISO, IATF, and customer audits.
• Ensure real-time ERP/MRP system updates for quality tracking and control.

Key Performance Indicators (KPIs):

• Rejection Rate (%): Percentage of defective parts produced.
• First Pass Yield (FPY %): Parts meeting quality standards without rework.
• Customer Complaint Reduction (%): Improvement in customer satisfaction due to fewer defects.
• Supplier Quality Performance (%): Incoming material acceptance rate.
• Cost of Poor Quality (COPQ): Cost impact of rework, scrap, and defects.
• Audit Compliance Score: Internal and external audit results.
• CAPA Effectiveness (%): Percentage of resolved quality issues with no recurrence.

Skills & Qualifications:

Educational Qualification:

• B.E. / B.Tech / M.E. / M.Tech in Mechanical, Production, Industrial, or Metallurgical Engineering.

Technical Skills:

• Strong knowledge of ISO 9001, IATF 16949, AS 9100, and customer-specific standards.
• Expertise in PPAP, APQP, FMEA, SPC, MSA, and RCA.
• Experience with CMM, Profile Projectors, Hardness Testers, and Surface Finish Testers.
• Familiarity with ERP/MRP systems for quality tracking.
• Proficiency in Lean Six Sigma methodologies (Green/Black Belt preferred).

Soft Skills:

• Leadership and team-building abilities.
• Strong problem-solving and decision-making skills.
• Effective communication and customer handling expertise.
• Analytical mindset with attention to detail.

Experience:

• 10+ years in Quality Assurance/Quality Control in Sheet Metal Fabrication, with at least 3-5 years in a leadership role