Quality Assurance Manager

Company Description

Prasanna Packaging Machinery Pvt Ltd specializes in manufacturing high-quality Filling and Sealing Machines, Tube Filling Machines, and Cartoning Machines. The company is a trusted provider of advanced packaging solutions designed to meet the needs of various industries. Known for reliability and innovation, Prasanna Packaging Machinery has established a strong reputation in the market. With a focus on precision and quality, the company's machines are engineered to optimize efficiency and productivity for its clients.

Location: Rabale, Navi Mumbai

# Role Overview

The QC Manager is responsible for establishing and maintaining a robust quality control system across incoming materials, in-process assemblies, and final machinery testing, ensuring compliance with customer specifications, food industry standards, and regulatory requirements. The role also drives vendor quality, defect reduction, and continuous improvement

# Key Responsibilities

1. Incoming Material (Inward) Quality Control

·        Develop and implement incoming inspection plans for

-         Raw materials (steel, polymers, bought-out components

-         Mechanical components

-         Pneumatic & electrical parts

·        Ensure compliance with:

-         Drawings, specifications, and standards

-         Vendor certifications (COA, test reports)

·        Maintain traceability of incoming materials

·        Drive vendor rating system based on quality performance

 2. In-Process / Sub-Assembly Inspection

·        Define QC checkpoints for:

-  Fabrication

-   Machining

-  Sub-assemblies (mechanical, pneumatic, electrical)

·        Ensure adherence to:

-         Assembly drawings

-         Torque standards, alignment, tolerances

·        Monitor:

-         Process capability

-         First-piece approval (FPA)

·        Identify recurring defects and implement corrective actions

3. Mechanical, Pneumatic & Electrical Testing

·        Oversee:

-         Dimensional inspection

-         Functional testing of assemblies

-         Pneumatic leak tests, pressure validation

-         Electrical continuity, safety, and control panel testing

·        Ensure calibration and validation of all testing equipment

 4. Final Machine Quality Inspection (Packaging Machinery)

·        Ensure final machines meet:

-         Customer specifications

-         Performance criteria (speed, accuracy, reliability)

·        Conduct:

-         Dry runs and trial runs

-         FAT (Factory Acceptance Test)

·        Verify:

-         Hygiene compliance (critical for dairy & food industry)

-         Safety standards (interlocks, guarding, electrical safety)

5. Vendor Quality Management

·        Monitor and control:

-         Vendor rejections

-         Rework levels

·        Conduct:

-         Vendor audits and development programs

·        Drive:

-         Root cause analysis for vendor defects

-         Supplier corrective actions (SCAR)

6. Internal Quality & Design Feedback

·        Analyze rejection trends to:

-         Identify design weaknesses

-         Recommend improvements to engineering team

·        Participate in:

-         Design reviews

-         Value engineering initiatives

7. Documentation & Compliance

·        Maintain:

-         Inspection reports

-         Quality records

-         NCR (Non-Conformance Reports)

·        Ensure compliance with:

-         ISO standards (e.g., ISO 9001)

-         Food-grade machinery requirements

8. Team Leadership

·        Lead QC inspectors and engineers

·        Train team on:

-         Inspection standards

-         Testing procedures

·        Build a culture of quality ownership

# Key Result Areas (KRAs)

 1. Incoming Quality Performance

·   Reduction in incoming rejection rate (%)

·        Vendor defect PPM improvement

·        On-time inspection clearance

2. In-Process Quality Control

·        Reduction in in-process defects

·        First-pass yield (FPY) improvement

·        Reduction in rework hours

3. Final Product Quality

·        Zero critical defects at dispatch

·        FAT pass rate (first attempt)

·        Customer complaints / warranty issues reduction

4. Vendor Quality Management

·        Vendor rejection trend reduction

·        Closure time for vendor corrective actions

·        Vendor rating improvement

5. Cost of Poor Quality (COPQ)

·        Reduction in:

-         Scrap cost

-         Rework cost

-         Warranty claims

6. Internal Quality Improvement

·        Number of design improvements initiated from QC insights

·        Reduction in recurring defects

·        Implementation of CAPA (Corrective & Preventive Actions)

7. Compliance & Documentation

·        Audit score (internal/external)

·        Zero major non-conformities

·        Documentation accuracy & completeness

8. Testing Effectiveness

·        % adherence to testing protocols

·        Calibration compliance (100%)

·        Downtime due to quality failures

9. Team Performance

·        Skill development index of QC team

·        Productivity per inspector

·        Training completion %

10.KPIs (Sample Measurable Targets)

·        Incoming rejection: < 2%

·        Vendor PPM: < 1000

·        FAT first-pass success: > 95%

·        Customer complaints: < 1 per 10 machines

·        COPQ reduction: 10–15% YoY

# Important Focus Areas (Critical for Your Setup)

1. Strong Vendor Control

·        Strict gatekeeping at inward stage

·        No bypass of QC for urgent production

 2. Design Feedback Loop

·        QC must not just inspect — it must challenge design flaws

·        Use data to escalate systemic issues

 3. Food Industry Compliance

·        Ensure:

-         Hygienic design validation

-         Contamination-free assembly

 4. Integrated Testing Approach

·        Combine:

-         Mechanical + Pneumatic + Electrical validation

·        Avoid siloed testing failures