JOB DESCRIPTION
Quality Section In-Charge – Enamel Department
Company: Vidya Wires Limited
Department: Quality
Section: Enamel
Level: Mid-Level / Section In-Charge
Location: Anand, Gujarat
Experience: 8–15 Years
Qualification: Diploma / B.E. / B.Tech. in Electrical, Mechanical, Production, Metallurgy or related field
Job Purpose
To control and maintain product quality in the Enamel Department by monitoring process parameters, conducting inspections and testing, ensuring compliance with quality standards, reducing defects and scrap, and supporting continuous process improvement.
Key Responsibilities
1. Enamel Process Quality
- Monitor quality parameters of enameled copper/aluminium wires during production.
- Ensure compliance with approved process specifications, SOPs and control plans.
- Monitor enamel coating, curing, adhesion, flexibility, insulation and surface quality.
- Ensure proper control of enamel viscosity, temperature, line speed and other critical parameters.
- Identify abnormal process conditions and coordinate corrective actions with Production.
2. Inspection & Testing
- Ensure in-process and final inspection of enameled wires as per defined standards.
- Monitor tests such as:
- Breakdown Voltage
- Adhesion / Flexibility
- Abrasion
- Thermal Shock
- Diameter / Build-up
- Pinholes
- Surface Appearance
- Enamel Coverage
- Review test results and ensure timely disposition of non-conforming material.
3. Defect & Scrap Control
- Analyse major enamel defects such as pinholes, blistering, poor adhesion, uneven coating, surface damage and enamel cracks.
- Monitor rejection and process scrap on a daily basis.
- Conduct root-cause analysis and implement corrective/preventive actions.
- Work with Production and Maintenance teams for reduction of recurring defects.
4. Documentation & Traceability
- Ensure proper completion and verification of quality records, inspection reports and production-related quality documents.
- Maintain product traceability from raw material to finished product.
- Verify calibration status of measuring and testing equipment.
- Support preparation and review of quality reports, CAPA and customer complaint records.
5. Team Supervision
- Guide and supervise Quality Engineers, Inspectors and Operators working in the Enamel Quality section.
- Allocate daily quality activities and ensure timely completion.
- Train team members on quality standards, defects, inspection methods and work instructions.
- Ensure discipline and adherence to safety and quality practices.
6. Customer Complaint & CAPA Support
- Support investigation of customer complaints related to enamel wire quality.
- Prepare or provide technical inputs for 8D / CAPA reports.
- Coordinate with Production, Process Engineering and Maintenance for corrective actions.
- Monitor effectiveness of corrective actions.
7. Continuous Improvement
- Identify opportunities for reduction of rejection, rework and scrap.
- Participate in process audits and quality improvement projects.
- Support SPC, process capability, MSA and other quality improvement activities where applicable.
- Promote "Right First Time" and zero-defect practices in the Enamel Department.
Key Skills
- Knowledge of enamelled copper/aluminium wire manufacturing.
- Knowledge of electrical insulation/enamel wire testing.
- Good understanding of Quality Control and Quality Assurance.
- Root Cause Analysis, 5 Why and Fishbone.
- 8D / CAPA knowledge.
- SPC and basic statistical analysis.
- Good documentation and reporting skills.
- Team handling and coordination ability.
- Good communication and problem-solving skills.
Preferred Experience
Experience in enameled copper/aluminium wire, winding wire, transformer wire, electrical conductor or similar manufacturing industry will be preferred.
Key Performance Indicators (KPIs)
- Enamel rejection and scrap %
- Customer complaints / PPM
- Process defects and rework %
- First Pass Yield
- Timely closure of CAPA
- Process parameter compliance
- Quality record compliance
- Calibration / testing compliance
- Reduction in recurring defects
