Job Summary
Lead all Site Quality Control (QC) and Quality Assurance (QA) functions, ensuring 100% compliance with Field Quality Assurance Plans (FQAP), technical specifications, and statutory requirements (IBR). The goal is zero-defect erection and timely mechanical completion.
Candidate Requirements
Education: Diploma / Bachelor of Engineering in Mechanical Engineering or an equivalent technical degree.
Experience: Total 10-18 years
of core experience in Site Quality Management, specifically within power plants, refineries, or heavy industrial construction projects.
Certifications: (Preferred) ASNT Level II in NDT (RT, UT, MPT, LPT), AWS/CSWIP welding inspection, or ISO Lead Auditor certification.
Key Responsibilities
Site Quality Control & Inspection Execution & Turnaround: Supervise, coordinate, and perform inspections of incoming materials, equipment, and field quality activities within 24 hours of an Inspection Call. Adherence to Standards: Ensure all activities align with technical requirements and approved procedures, including FQP (Field Quality Plan), FWS (Field Welding Schedule), HPS, and SOPs. System Completion: Conduct Erection Completion Certificate (ECC) checks and perform final walk-downs prior to all Hydro-tests, ensuring the completion of all NDTs (Non-Destructive Testing) and visual checks for pressure parts and piping joints. Mechanical Inspections: Attend and oversee inspections for critical mechanical items, including Pressure Parts, Technological Structures, Plates, Forgings, Pressure/Non-pressure piping, Pressure Vessels, EOT Cranes, Wind Boxes, Coal Burner Bodies, Fans, Dampers, and Valves. Quality Assurance & Process Improvement Defect Management: Record, analyse, and control the weld defect rate to remain <2%. Provide timely guidance to welders and grinders to achieve sound weld quality and minimize repairs.
Continuous Improvement: Implement Mistake Proofing at the site to prevent defect occurrence and drive Kaizen processes for cost reduction. Non-Conformance Management: Identify non-conformities (NCRs) regarding incoming material, transit damages, or erection errors. Initiate NCRs in the Tbits system, follow up with Engineering/HQ for recommendations, and verify closure with the execution team including Root Cause Analysis (RCA) and CAPA (Corrective and Preventive Action). Documentation & Statutory Compliance Pre-Planning: Provide required site QA documents and approvals to the site erection team or contractor at least 07 days prior to the start of activities. Regulatory Compliance: Obtain necessary statutory compliances, specifically IBR (Indian Boiler Regulations) clearance. Reporting: Prepare and submit the Quality MIS to management. Review and issue Inspection Reports (IR) and Inspection Release Notes (IRN). Change Management: Supervise and track Design Change Notices (DCN) and Field Change Notices (FCN) at the site, ensuring approval of rectification procedures. Vendor & Contractor Management Vendor Selection: Handle Inspection Agency selection, negotiation, and vendor assessment prior to contract finalization. Audit & Supervision: Assessment of contractors through verification and controlling processes. Conduct site audits on a fortnightly basis. Coordination: Liaison with Third Party Inspection Agencies (TPIA), Manufacturers, Consultants, and Clients. Finalize invoicing and receipt status for inspection agencies. Expediting: Monitor progress related to inspections and expedite delayed items to ensure timely delivery. Leadership, Training & Audits Team Development: Provide adequate training to enhance the technical knowledge of team members, contractors, and sub-contractors. Mentorship: Provide on-site job training for GETs (Graduate Engineer Trainees) and specific training for NDT technicians. Auditing: Conduct CFT, Client, and ISO Audits at the site. Review Meetings: Hold joint meetings with the client and execution team to address backlogs (specifically analysing NDT backlogs) and create catch-up plans.
Required Competencies
- Technical Knowledge: Deep understanding of WPS (Welding Procedure Specification), PQR (Procedure Qualification Record), WQR, and FWS.
- Technical Expertise: Deep knowledge of Pressure Parts, Heavy Structures, Piping, and Mechanical Equipment (Pumps, Fans, EOT Cranes).
- Standards: Proficiency in IBR, ISO, and site-specific FQAP.
- Analytical Skills: Ability to perform Why-Why analysis for corrective and preventive actions.
- Communication: Strong ability to liaise with clients and negotiate with vendors.
