1. Job Purpose
To ensure the quality of Copper Busbar, Rolled Copper, Up-Cast Copper and Copper Components by effectively controlling incoming material, in-process and final product quality, reducing rejection and rework, resolving quality problems and ensuring compliance with customer specifications, drawings and applicable standards.
2. Key Responsibilities
A. In-Process & Final Quality Control
- Monitor quality of products manufactured in the assigned sections.
- Ensure inspection of raw material, in-process material and finished products.
- Check product dimensions, surface quality, conductivity, mechanical properties and other specified parameters.
- Ensure products are manufactured as per approved drawings, specifications and quality standards.
- Approve first-piece / first-off samples before regular production.
- Ensure proper final inspection before releasing products to Stores / Dispatch.
- Identify and immediately report quality deviations to Production and Quality Head.
B. Process Quality – Up-Caster & Rolling Mill
- Monitor quality parameters of the Up-Casting and Rolling Mill processes.
- Identify defects such as cracks, scratches, surface defects, dimensional variation, edge defects and other abnormalities.
- Coordinate with Production and Maintenance for correction of process-related quality problems.
- Monitor critical process parameters and ensure adherence to defined standards.
- Maintain quality records and analyse recurring defects.
C. Copper Busbar & Components Quality
- Inspect Copper Busbars and Copper Components as per customer drawings and specifications.
- Check:
- Width
- Thickness
- Length
- Hole / slot dimensions
- Straightness / flatness
- Surface finish
- Burrs and edge condition
- Conductivity
- Other customer-specific requirements
- Ensure proper identification and segregation of OK, Hold, Rework and Rejected material.
- Verify reworked material before final acceptance.
D. Rejection & Quality Improvement
- Monitor daily rejection, rework and scrap.
- Analyse major quality problems and identify their root causes.
- Conduct 5 Why / Fishbone / Pareto analysis wherever required.
- Implement corrective and preventive actions with Production and other concerned departments.
- Work continuously to reduce internal rejection, rework and quality losses.
- Take initiatives for improving First Pass Yield and Right First Time (RFT).
E. Customer Complaints
- Support investigation of customer complaints.
- Analyse complaint samples, inspection data and process records.
- Coordinate with Production and other departments to identify root causes.
- Prepare corrective action / 8D / CAPA reports wherever required.
- Ensure timely closure of customer complaints.
- Monitor repeat complaints and take preventive action.
F. Measuring & Testing Equipment
- Ensure availability of required measuring and testing instruments.
- Ensure instruments are properly calibrated.
- Maintain calibration records.
- Prevent use of damaged or expired calibration instruments.
- Ensure proper handling and storage of measuring equipment.
G. Quality Documentation
Maintain proper records of:
- Incoming inspection
- In-process inspection
- Final inspection
- Test reports
- Rejection / rework
- NCRs
- Customer complaints
- Corrective actions
- Calibration
- First-piece approval
- Quality performance reports
H. Team Management
- Supervise Quality Inspectors / Engineers / Technicians working in the assigned area.
- Allocate inspection responsibilities and monitor their work.
- Train team members on product specifications, inspection methods and measuring instruments.
- Ensure discipline, attendance, safety and proper working practices within the Quality team.
- Develop technical skills of team members.
I. Coordination
Coordinate closely with:
- Production – Process control and rejection reduction
- Maintenance – Machine-related quality problems
- PPC – Production planning and inspection requirements
- Purchase / Stores – Incoming material quality
- R&D / Technical – New products and specifications
- Sales / Customer Service – Customer complaints and technical requirements
3. Key Quality Areas
The incumbent will be primarily responsible for:
- Copper Up-Caster quality
- Copper Rolling Mill quality
- Copper Busbar quality
- Copper Component quality
- Dimensional accuracy
- Electrical conductivity
- Surface quality
- Mechanical properties
- Customer specification compliance
- Process quality
- Rejection and rework control
Education
- Diploma / B.E. / B.Tech. in Mechanical / Production / Electrical Engineering or relevant discipline.
Experience
- 5–10 years of relevant experience in Quality Control / Quality Assurance.
- Experience in Copper / Aluminium / Non-Ferrous Metal / Busbar / Rolling Mill / Continuous Casting / Electrical Conductor manufacturing will be preferred.
4. Technical Skills
The candidate should have knowledge of:
- Copper manufacturing processes
- Up-Casting / Continuous Casting
- Rolling Mill process
- Copper Busbar manufacturing
- Copper Components
- Dimensional inspection
- Electrical conductivity testing
- Mechanical testing
- Engineering drawings
- Measuring instruments
- SPC and basic statistical tools
- 7 QC Tools
- 5 Why / Root Cause Analysis
- CAPA / 8D
- Calibration
- Quality documentation
