Team Lead II / Senior Operator II, Manufacturing Process Quality

1.

Job Purpose

To ensure that all incoming raw materials, bought-out items, and sub-assemblies used in transformer manufacturing comply with approved specifications, drawings, standards, and quality requirements before being released for production.

2.

Key Roles & Responsibilities

2.1 Incoming Material Inspection

• Inspect all incoming materials related to transformer manufacturing as per Incoming Quality Plans (IQP).

• Verify materials against approved drawings, BOMs, purchase orders, and specifications etc.

• Perform inspection on critical items including:

o Copper conductors (wire/strip), PICC/CTC etc

o CRGO/core laminations

o Insulation materials (pressboard, epoxy boards, paper, spacers)

o OLTC components and transformer accessories/ OCTC

o Bushings

o Transformer Oil

• Ensure materials are received only from approved suppliers.

(Must follow Customer approved make if specified)

2.2 Visual & Dimensional Inspection

• Conduct visual inspections to identify defects such as:

o Cracks, dents, warpage, rust, contamination

o Delamination, oil leakage marks, or physical damage

• Carry out dimensional inspection using:

o Vernier callipers, micrometres, gauges, templates

• Ensure conformance to specified tolerances and standards.

2.3 Material Identification & Traceability

• Verify material grade, batch/lot number, heat number, and supplier identification.

• Ensure proper tagging and identification of:

o Accepted material

o Rejected material

o Material under hold or review

• Prevent mixing of approved and unapproved materials.

2.4 Documentation Verification

• Review and validate supplier quality documents including:

o Test Certificates (TC)

o Material Test Reports (MTR)

o Certificates of Conformance (CoC)

• Ensure compliance with IS/IEC standards, customer specifications, and internal procedures.

• Report any document discrepancies immediately.

• Prepare, update, and regularly maintain the GRN Hold List and Quarantine Material List, ensuring timely status updates and proper material control.

• Compile, prepare, and maintain Bought-Out Test Certificates (BOTC) strictly as per Customer-Approved Quality Assurance Plan (QAP).

• Submit complete and verified BOTC documentation to the customer prior to and during Factory Acceptance Testing (FAT).

2.5 Handling of Non-Conforming Material

• Identify, segregate, and control non-conforming or rejected materials.

• Ensure to put rejected material in defined Quarantine zone.

• Raise NCRs / Rejection Reports for deviations or defects.

• Coordinate with Quality, Stores, Purchase, and Supplier Quality teams for disposition.

2.6 Supplier & Internal Coordination

• Communicate inspection results to relevant internal departments.

• Support supplier quality improvement activities through clear defect reporting.

• Assist in re-inspection, supplier visits, and quality follow-ups as required.

2.7 Quality System Compliance

• Follow ...