Incharge - In‑Process Quality

Job Description - Manager, In-Process Quality Electronic Control Panel Manufacturing Unit (Wind Turbine Generators) Position Details Particulars Details Position Title Manager - In-Process Quality Department Quality Assurance Reporting To Head - Quality Location Electronic Control Panel Manufacturing Unit Grade Manager Job Purpose To lead and manage all in-process quality assurance activities across the Electronic Control Panel manufacturing value stream, ensuring that products are built in accordance with customer specifications, engineering drawings, approved work instructions, statutory requirements, and internal quality standards. The role is responsible for preventing defects through process control, quality inspections, root cause analysis, corrective actions, and continuous improvement initiatives to achieve zero-defect manufacturing and customer satisfaction. Key Roles & Responsibilities Quality Control & Assurance Develop and implement in-process quality control plans for all control panel manufacturing activities. Ensure adherence to approved manufacturing processes, quality standards, drawings, BOMs, and work instructions. Lead stage-wise inspections across: Plate preparation and fabrication Component mounting Bus bar preparation and assembly Wire cutting, ferruling and crimping Internal wiring and interconnections Labeling and identification Mechanical assembly Final panel integration Verify conformity of assemblies against approved engineering drawings and customer requirements. Ensure compliance with IPC, electrical safety, and internal quality standards wherever applicable. Process Quality Management Establish quality checkpoints at critical manufacturing stages. Monitor process capability and identify opportunities for defect prevention. Drive First Pass Yield (FPY) improvements across assembly lines. Ensure implementation of quality gates before movement to the next production stage. Review and approve in-process inspection records and quality reports. Non-Conformance Management Lead investigation of in-process quality issues and non-conformities. Conduct Root Cause Analysis using: 8D Why-Why Analysis Fishbone Diagram Pareto Analysis Implement corrective and preventive actions (CAPA). Monitor effectiveness of corrective actions and prevent recurrence. Team Leadership Lead and mentor quality inspectors and quality engineers. Allocate inspection resources based on production schedules. Conduct skill assessment and training programs for quality personnel. Build a quality-focused culture on the shop floor. Coordination & Cross Functional Support Coordinate closely with: Production Manufacturing Engineering Planning Procurement Supplier Quality Design Engineering Stores Participate in product and process change reviews. Support new product introduction and localization projects from a quality perspective. Quality System Compliance Ensure compliance with ISO 9001 requirements and company QMS procedures. Maintain quality documentation, inspection records, process audit reports, and CAPA records. Support internal audits, customer audits, and certification audits. Monitor adherence to calibrated measuring instruments and testing equipment. Continuous Improvement Lead quality improvement projects to reduce: Internal rejection Rework Process variation Customer complaints Promote Poka-Yoke and mistake-proofing initiatives. Drive Lean Manufacturing and continuous improvement practices impacting quality performance. Key Accountabilities Area Accountability In-Process Quality Ensure stage-wise inspection compliance and defect prevention Process Control Maintain robust quality control plans and inspection systems Quality Performance Improve FPY and reduce rejection/rework levels CAPA Timely closure of quality concerns and corrective actions Audit Compliance Compliance with ISO and customer quality requirements Team Development Development and competency enhancement of quality personnel Customer Focus Minimize customer quality issues through strong process controls Key Performance Indicators (KPIs) First Pass Yield (FPY) In-Process Rejection Rate Rework Percentage Cost of Poor Quality (COPQ) Corrective Action Closure Rate Internal Audit Scores Customer Complaint Trend Process Audit Compliance % Defects Per Million Opportunities (DPMO) Training Effectiveness of Quality Team Educational Qualification B.E./B.Tech in Electrical & Electronics Engineering (EEE), Electrical Engineering, Electronics & Communication Engineering (ECE), Mechanical Engineering, or related discipline. Quality certifications such as Six Sigma Green Belt, Internal Auditor Certification, or Quality Management certifications preferred. Experience 10-15 years of experience in Quality Assurance/Quality Control. Minimum 5 years of experience in electronic control panel manufacturing, switchgear manufacturing, electrical equipment manufacturing, industrial automation panels, or similar industries. Experience in managing shop-floor quality teams and customer audits. Position Specific Requirements Strong understanding of electrical control panel manufacturing processes. Knowledge of electrical schematics, GA drawings, wiring diagrams, and BOM structures. Experience in inspection of wire harnesses, bus bars, electrical assemblies, and control panels. Understanding of crimping standards and wiring quality requirements. Familiarity with testing and inspection practices for control panels. Exposure to quality tools, statistical techniques, and problem-solving methodologies. Experience in SAP HANA or ERP-based quality documentation systems. Knowledge of ISO 9001 quality systems and audit requirements. Key Skills & Competencies Technical Skills In-Process Quality Management Electrical Control Panel Inspection Root Cause Analysis (RCA) CAPA Management Process Audits First Pass Yield Improvement Quality Documentation Interpretation of Electrical Drawings Statistical Quality Control Lean Manufacturing Six Sigma Methodologies Quality Management Systems (QMS) Behavioral Competencies Leadership & Team Management Analytical Thinking Attention to Detail Decision Making Problem Solving Cross-Functional Coordination Coaching & Mentoring Planning & Organizing Customer Orientation Continuous Improvement Mindset Prior Exposure/Familiarity Preferred Wind Turbine Generator manufacturing. Industrial control panels and automation systems. Switchgear and electrical assembly manufacturing. Customer quality audits and quality compliance requirements. Lean, Kaizen, and operational excellence initiatives. High-mix, low-volume manufacturing environments.