Incharge - Testing & Outgoing Quality

Job Description - Manager, Outgoing Quality, Testing & Dispatch Electronic Control Panel Manufacturing Unit (Wind Turbine Generators) Position Details Particulars Details Position Title Manager - Outgoing Quality, Testing & Dispatch Department Quality Assurance Reporting To Head - Quality Location Electronic Control Panel Manufacturing Unit Grade Manager Job Purpose To lead and manage all outgoing quality assurance, functional testing, pre-dispatch inspection, packing validation, and dispatch quality activities for Electronic Control Panels used in Wind Turbine Generators. The role is responsible for ensuring that only fully compliant, tested, customer-approved products are dispatched, while maintaining adherence to quality standards, testing procedures, customer specifications, and statutory requirements. Key Roles & Responsibilities Outgoing Quality Management Establish and maintain robust outgoing quality control processes for all control panels prior to dispatch. Ensure 100% compliance of finished products against approved drawings, BOMs, customer specifications, and quality standards. Approve product release only after successful completion of all testing and inspection requirements. Verify closure of all internal non-conformities before dispatch clearance. Monitor outgoing quality performance and implement corrective actions for recurring quality issues. Testing Management Lead all electrical and functional testing activities of finished control panels. Ensure compliance with approved test plans, FAT (Factory Acceptance Test) procedures, and customer specifications. Supervise and validate testing activities such as: Continuity Testing Insulation Resistance (IR) Testing High Voltage (Hi-Pot) Testing Functional Testing PLC I/O Verification Relay Logic Verification Communication Testing Interlock Verification Loop Checking Power-Up Testing Ensure proper recording and traceability of all test results. Verify calibration status of testing equipment and instruments. Final Inspection & Release Conduct final inspection of completed panels before shipment. Verify: Component correctness Wiring quality Ferruling and labeling Nameplates Mechanical assembly Bus bar installation Terminal tightness Documentation completeness Ensure product identification and traceability requirements are met. Authorize final quality release for dispatch. Dispatch Quality Assurance Establish dispatch inspection checkpoints. Verify packaging adequacy for transportation and handling. Ensure protection against moisture, damage, vibration, and corrosion during transit. Validate packing specifications, marking requirements, and shipping labels. Coordinate with logistics and stores teams to ensure safe loading and dispatch practices. Review dispatch documentation before shipment. Customer Inspection Support Coordinate customer inspections, FAT activities, and third-party inspections. Ensure timely closure of customer observations. Act as the quality representative during customer visits and dispatch approvals. Support customer-specific quality documentation requirements. Non-Conformance & CAPA Management Investigate outgoing quality failures and customer-reported field issues. Conduct Root Cause Analysis using: 8D Methodology Why-Why Analysis Fishbone Analysis Pareto Analysis Drive corrective and preventive actions across manufacturing processes. Monitor effectiveness of implemented actions. Team Leadership Lead and manage testing engineers, quality engineers, and outgoing inspectors. Allocate manpower based on production and dispatch schedules. Develop testing competencies within the team. Conduct periodic skill enhancement and calibration awareness training. Quality Systems & Compliance Ensure compliance with ISO 9001 Quality Management System requirements. Maintain testing records, inspection reports, quality release notes, and dispatch quality documentation. Support customer audits, certification audits, and internal audits. Ensure traceability of finished products and quality records. Continuous Improvement Reduce customer complaints through effective outgoing quality controls. Improve First Time Pass Rate during final testing. Implement mistake-proofing (Poka-Yoke) initiatives in testing and dispatch processes. Drive continuous improvement projects focused on quality, reliability, and customer satisfaction. Key Accountabilities Area Accountability Final Product Quality Ensure only conforming products are dispatched Testing Compliance Complete testing as per approved procedures Dispatch Readiness Ensure safe and damage-free dispatch of products Customer Satisfaction Minimize customer complaints and warranty issues Traceability Ensure complete product and test record traceability Quality Documentation Maintain accurate testing and inspection records Team Management Develop testing and outgoing quality capabilities Key Performance Indicators (KPIs) Final Testing First Pass Yield (FPY) Customer Complaint Rate Dispatch Rejection Rate Warranty Claim Incidents Outgoing Quality Defect Rate FAT Success Rate Corrective Action Closure Effectiveness On-Time Dispatch Clearance Audit Compliance Score Calibration Compliance Percentage Educational Qualification B.E./B.Tech in Electrical & Electronics Engineering (EEE), Electrical Engineering, Electronics & Communication Engineering (ECE), Instrumentation Engineering, or related discipline. Additional certifications in Quality Management, Testing, Six Sigma, or Internal Auditing will be preferred. Experience 10-15 years of experience in Quality Assurance, Testing, or Electrical Manufacturing. Minimum 5 years in managing final quality inspection and testing operations. Experience in electrical control panel manufacturing, switchgear manufacturing, automation systems, or similar industries. Exposure to customer FATs, dispatch inspections, and quality release processes. Position Specific Requirements Strong understanding of control panel manufacturing and testing processes. Expertise in electrical schematic interpretation and troubleshooting. Knowledge of PLC-based control systems and industrial automation panels. Experience in FAT and customer inspection management. Familiarity with electrical safety standards and testing practices. Knowledge of calibration management and measurement systems. Understanding of dispatch packaging requirements for industrial equipment. Working knowledge of SAP HANA or ERP systems for quality documentation and traceability. Key Skills & Competencies Technical Skills Outgoing Quality Management Electrical Panel Testing Factory Acceptance Testing (FAT) Functional Verification High Voltage & Insulation Testing PLC and Control Logic Validation Quality Release Management Root Cause Analysis (RCA) CAPA Management Calibration Control Quality Audits Quality Documentation & Traceability Behavioral Competencies Leadership & Team Development Analytical Thinking Decision Making Attention to Detail Customer Orientation Problem Solving Planning & Organizing Cross-Functional Coordination Communication Skills Continuous Improvement Mindset Prior Exposure/Familiarity Preferred Wind Turbine Generator Control Panel Manufacturing. Power Conversion and Control Systems. Industrial Automation and SCADA Panels. Switchgear and Electrical Equipment Manufacturing. Customer FAT and Third-Party Inspection Processes. Lean Manufacturing, Six Sigma, and Operational Excellence Programs. Domestic and Export Dispatch Quality Requirements.