Overview

Handling of PC 32 and 21 lines at Channo plant with right quality product & building a quality culture in the plant.
Stabilization of shift quality operations.
Ensuring shifts KPIs such as WIP/ Leakages/ Zero red complaints.
Ensuring best quality of product and minimum customer complaints through stringent on-line quality control checks and finished product inspection
Implementing right quality control systems/standards for the processes, physical systems and environment.
Trouble shooting during online production to minimize wastage and ensure quality.
Responsible for maintaining GMP, GHK GLP and internal / external audits (HACCP, AIB, Personal Hygiene, Process audit).
Train and development of quality checkers.
Ensure quality of potato issued for production.

Responsibilities

Conducting online quality checks in the process area to ensure that all Pepsico standards of quality are followed during the production process in shifts

Conducting visual inspection for;
Ensuring that all key operating parameters of machines are in the specified range
(Peelers, Fryers, Slicer for thickness average and range, Chip Conveyors, Seasoning Tumbler)
Ensuring after every hour that the potatoes in the trim and pare area are properly peeled
Checking slice thickness and free surface moisture after every 4 hours
Deciding whether to introduce anti-foaming agent in the process
Recording the dwell time from the operator's logbook after every 4 hours
Checking the level of seasoning applied
Conducting analytical tests for
Deciding whether blanching is required - Hunter Color Test
Ensuring optimum utilization of fryer oil
Conducting 4 hourly checks on oil being used for frying for FFA, OV, PV, foreign materials, taste, odor and specific gravity
Comparing test results against gold standards oil usage charts
Deciding the mix of fresh and blended oil to be used for frying operations
Checking the fried chips after every hour for TPD parameters like PA, percentage oil in the chip, % of soft centered chips, blisters, dark flakes, clusters etc.
Measuring parameters like bulk density, moisture, seasoning and dimension for Non-PC products

Taking corrective actions to resolve problems thrown up by the tests

Providing feedback to operators on corrective actions that can be taken for rectifying small problems
Communicating to the shift in-charge the number of pickers needed for the process area on the basis of online checks
Asking the Agro department to change the potato lot in case there are no pickers and the number of potato defects are large
Communicating concern areas and corrective actions to the concerned shift in-charge and production manager promptly
Informing the Quality Manager in case test results indicate a crisis situation, who will then conduct a compete trial run of that lot of potato to take an appropriate decision

Conducting online quality checks and finished products inspection in the packaging area to ensure compliance with Frito Lay standards of quality

Ensuring that the Quality Checkers conduct half hourly checks for air leakage and hourly checks for weight, batch printing and air fill
Conducting analytical tests for
Checking after every four hours the percentage of oxygen in the bags - Nitrogen Flushing tests
Conducting random film quality checks on the basis of any special complaints received from the production department
Communicating concern areas and corrective actions to the concerned operator, shift in-charge and production manager promptly
Consulting the quality manager in case of criticalities
Ensuring that the corrective action is implemented

Monitoring machines in the process and packaging area specifically for their effect on quality and ensuring minimum waste due to machine related factors

Calibration of machines like FL 710e that detects moisture and % of oil in the chips after they are fried
Ensuring that the slicer blade is changed after every 1 and ½ hour
Ensuring that the peeler rollers are changed periodically to avoid under or over peeling
Maintaining accurate and comprehensive reports for communication to all the people concerned
Ensuring that the quality checkers make an end of shift report (for air leakage) at the end of every shift and then circulate it amongst the concerned people (quality, engineering, production)
Filing these reports on a daily basis
Filling the Weak Link Form to record the results of the oil tests
Making a Daily Quality Report for the Quality Manager
Updation of reports
Ensuring that the operators make quality relevant entries in their log books after every ½ hour
Conducting regular quality wall meetings with the production and engineering personnel for discussing quality defects detected online and then deciding the measures to rectify the problems
Coordinating a Take Action Wall meeting after every 4 hours
Ensuring that at least four people viz. shift incharge, packaging leader, engineering executive and the quality officer are present for the meeting
Comparing the product with the gold standard for appearance, flavor, texture and recording the ratings given to the product (ratings will vary between 0-10)
Deciding on appropriate action for the product on the basis of the test scores
Coordinating a Mini Wall Meeting after an hour of the Take Action Meeting to ensure that the recommended action has been carried out and the problem has been rectified
Calling for a Hot Wall meeting in case there is a critical problem

Conducting a weekly housekeeping audit to ensure implementation of safety and hygiene practices

Inspecting the process and packaging area to ensure that the working conditions like lighting, placement of material on the shop floor are as per standard requirements and that there are no unsafe conditions in the plant
Ensuring that the equipment have been cleaned properly on the previous Saturday
Conducting visual inspection to ensure that all the hold material of the previous week is cleared
Ensuring that pest control is done regularly in the plant
Getting non-compliances rectified before start-up

Handling the hold material for minimizing wastages

Ensuring that the hold material is cleared within 24-48 hours of hold-up
Submitting a weekly and monthly report to the quality manager regarding the details of the hold material, reasons for the hold-up
Awarding Red, White and Yellow Non-Compliance Disposition (NCD) Tags to the hold material after detailed analysis
Reporting the status of the tags to the production department stating the reasons for hold-up

Ensuring adherence to statutory laws (Weights and Measures & FSSAI )

Increasing awareness about statutory laws
Maintaining accurate statutory records

Effective resolution of customer complaints

Assisting the quality manager in analyzing root causes of complaint and developing a forward action plan
Implementing the action plan
Ensuring the complaint does not occur again

Participating in TPM activities for increased involvement in the functioning of the plant

Leading/ participating in TPM for various projects undertaken by them.

Practicing a Work Culture That Promotes Company Growth

Internalizing quality standards and concept of cost of quality
Executing the action plans to institutionalize these
Providing regular feedback to the quality manager on culture
Implementing change initiatives and continuous improvement in own department and plant
Identifying areas of improvement and highlighting these to Quality Manager
Implementing the action plans developed by the Quality Manager for continuous change
Ensure compliance with SOX and perform all roles and responsibilities as a Control Owner of I2C process
Documenting all quality procedures, systems, standards, findings, hazards and corrective actions

Additional Information, Interactions / Complexity

Interact with internal stake holders daily, weekly, Monthly basis such as packaging leader, Shift Incharge, maintenance coordinators for equipment corrections as Pepsico standards.
External: CFA, 3P, Distributor, Sales
Proper training and handholding of Quality checks
Having site leadership team support is critical for the SET to deliver results
Handling the IR situations of Quality (QC), managing Contract Labours @shop floor

Qualifications

Tech ( Food Tech)/ M.Sc. Food Tech or any relevant subjects.
Exposure to food safety systems and ISO systems / 3 to 5 years.
Preferably Knowledge of FSSAI /HACCP/AIB and TPM.

Quality Executive

Shift Engineer/ Site Engineer

Network Engineer

CDP / Head Chef

ORMB Developer

Head Chef

FSE for MRI + CT- Across Maharashtra