Quality Manager – Manufacturing Quality Assurance & Control

About the Role

Celestix Industries is establishing a large-scale greenfield manufacturing campus in Falna, Rajasthan, comprising multiple factories focused on wiring harness manufacturing, copper busbar manufacturing, precision sheet metal fabrication, structural steel fabrication and industrial electrical components.

We are looking for an experienced, technically strong and hands-on Quality Manager / Quality Assurance Manager / Quality Control Manager to establish, implement and lead the Quality Assurance (QA) and Quality Control (QC) functions across the manufacturing campus.

This is a senior manufacturing quality leadership position suitable for an experienced Quality Head or QA QC Manager with proven experience managing quality systems, production quality, supplier quality, customer quality, factory audits and continuous improvement.

During the initial greenfield setup phase, the selected candidate will be responsible for developing quality management systems, establishing inspection procedures, identifying measuring instruments and testing equipment, recruiting and training quality personnel, reviewing customer specifications and ensuring quality readiness before commercial production begins.

Once the manufacturing facilities become operational, the Quality Manager will take responsibility for end-to-end manufacturing quality, including incoming material inspection, in-process quality control, final product inspection, supplier quality, nonconforming material control, customer complaints, corrective and preventive actions, internal audits and ongoing quality improvement.

The manufacturing campus is planned to include:

• Wiring harness and cable assembly manufacturing
• Copper busbar manufacturing and fabrication
• CNC sheet metal cutting, bending, punching and machining
• Structural steel fabrication and welding
• Electrical and precision metal components
• Associated manufacturing, inspection, testing and finishing processes

The most important requirement is proven experience in manufacturing quality management, combined with strong practical knowledge of inspection systems, root cause analysis, quality standards, customer requirements and the ability to independently establish a quality department for a new manufacturing facility.

This is not a desk-only documentation or audit coordination position.

The selected candidate must be comfortable working directly with Production Managers, Production Engineers, Quality Engineers, inspectors, machine operators, suppliers and customer representatives to prevent defects and resolve manufacturing quality problems.

Key Responsibilities

1. Greenfield Factory Quality Setup & Quality Department Establishment

The Quality Manager will play a central role in establishing the quality function for the new manufacturing campus.

Responsibilities include:

• Develop a phased quality department setup and operational readiness plan.
• Establish Quality Assurance and Quality Control systems across manufacturing divisions.
• Review manufacturing processes and identify inspection and testing requirements.
• Participate in factory layout planning for inspection stations, quality laboratories and testing areas.
• Recommend appropriate measuring instruments, gauges, testing equipment and inspection fixtures.
• Establish incoming, in-process and final inspection procedures.
• Prepare quality-related standard operating procedures (SOPs), work instructions and documentation.
• Identify product-specific quality requirements and customer specifications.
• Support machinery commissioning and process validation.
• Develop quality manpower requirements for the initial commissioning and production stages.
• Participate in recruitment of Quality Engineers, Quality Supervisors and inspectors.
• Establish quality training programs for inspectors and production personnel.
• Coordinate quality readiness during trial production and manufacturing ramp-up.
• Ensure quality requirements are incorporated before manufacturing processes are released for regular production.
• Establish quality performance reporting and corrective action systems.

The objective is to develop a practical, reliable and scalable quality management function capable of supporting multiple manufacturing divisions.

2. Quality Management Systems (QMS) & ISO 9001

Lead the development, implementation and continual improvement of the manufacturing Quality Management System.

Responsibilities include:

• Develop and maintain factory-wide QMS procedures and controls.
• Implement applicable requirements of ISO 9001 and customer-specific quality systems.
• Establish quality policies, objectives and departmental responsibilities in coordination with management.
• Maintain appropriate quality manuals, procedures, inspection plans and documented information.
• Develop document control and revision management procedures.
• Establish processes for control of nonconforming products.
• Maintain corrective and preventive action systems.
• Coordinate internal quality audits and management reviews.
• Ensure departments follow approved quality procedures.
• Maintain quality records and evidence of process compliance.
• Coordinate certification or surveillance audits within the approved certification scope.
• Identify system gaps and implement improvements.

The candidate should have strong practical knowledge of implementing QMS requirements in an operating manufacturing environment.

3. Incoming Material Quality Control (IQC)

Establish and manage incoming inspection systems for raw materials, purchased components and outsourced manufacturing services.

Materials and components may include:

• Electrical wires and cables
• Terminals and connectors
• Connector housings and accessories
• Copper bars and flats
• Steel sheets and plates
• Stainless steel and aluminium materials
• Welding consumables
• Machined components
• Fabricated components
• Plated and coated components
• Customer-specific purchased parts

Responsibilities include:

• Develop incoming inspection procedures and acceptance criteria.
• Verify supplier material specifications, drawings and certificates.
• Establish appropriate incoming sampling and testing plans.
• Coordinate inspection of dimensions, material grades and critical characteristics.
• Identify nonconforming incoming material.
• Ensure rejected materials are identified, segregated and controlled.
• Coordinate supplier quality issues with Procurement and Engineering.
• Maintain incoming inspection records and material traceability.
• Support supplier corrective actions and continuous improvement.

4. Wiring Harness & Cable Assembly Quality Management

Manage quality requirements for wiring harness and cable assembly manufacturing.

The candidate should understand or be capable of leading specialists responsible for:

• Wire cutting and stripping quality
• Terminal crimping
• Crimp-height verification
• Pull-force testing
• Conductor and insulation crimp requirements
• Terminal insertion
• Connector assembly
• Wire splicing and soldering
• Ultrasonic welding
• Harness routing and taping
• Wire and connector identification
• Continuity testing
• Electrical testing
• Final visual inspection
• Product traceability

Responsibilities include:

• Establish wiring harness inspection plans and acceptance criteria.
• Ensure critical crimping processes are controlled.
• Coordinate first-piece and in-process inspection.
• Ensure appropriate inspection of cutting lengths, strip lengths and assembly dimensions.
• Review crimping defects and recurring manufacturing problems.
• Establish controls for incorrect terminal insertion, damaged wires, connector defects and wiring errors.
• Ensure continuity and electrical testing are performed according to approved customer requirements.
• Coordinate defect analysis with Production and Engineering.
• Implement corrective actions to reduce rejection and rework.

Working knowledge of IPC/WHMA-A-620 requirements for cable and wire harness assemblies is strongly preferred.

5. Copper Busbar Manufacturing Quality

Establish quality control systems for copper busbar manufacturing processes.

Processes may include:

• Copper cutting and shearing
• CNC punching
• Drilling and machining
• Copper bending and forming
• Deburring
• Cleaning and surface preparation
• Plating and insulation coordination
• Final inspection

Quality requirements may include:

• Copper material grade and specifications
• Material dimensions
• Length, width and thickness
• Hole diameter and positioning
• Slot dimensions
• Bend angles and bend radius
• Flatness and parallelism
• Twisting and alignment
• Burr and edge condition
• Contact surface quality
• Surface cleanliness
• Plating thickness and coverage, where specified
• Insulation thickness and coverage, where specified
• Product identification and traceability

Responsibilities include:

• Establish incoming copper material inspection procedures.
• Coordinate verification of material certificates and customer specifications.
• Develop in-process quality control plans for cutting, punching, bending and machining.
• Ensure suitable measuring instruments and inspection fixtures are available.
• Monitor copper manufacturing defects and rework.
• Coordinate corrective action for dimensional and surface-quality problems.
• Ensure product traceability is maintained where required.
• Review quality problems involving plated, insulated or outsourced components.
• Support customer inspection and product acceptance requirements.

6. Sheet Metal Fabrication Quality Control

Manage quality requirements for CNC sheet metal cutting, bending and fabrication operations.

Responsibilities include:

• Establish dimensional inspection procedures for laser-cut and formed components.
• Monitor cutting accuracy, hole positions, profiles and tolerances.
• Ensure inspection of burrs, dross, incomplete cuts and surface damage.
• Coordinate first-piece inspection of CNC cutting programs.
• Establish bending inspection requirements for angles, flange dimensions and overall component geometry.
• Monitor springback, twisting and dimensional deviations.
• Verify appropriate inspection of punched and machined features.
• Ensure approved drawings and revisions are followed.
• Coordinate root cause analysis for repeated fabrication defects.
• Support reduction of scrap and rework.

The candidate should understand the practical inspection requirements of precision sheet metal fabrication.

7. Structural Welding & Fabrication Quality

Coordinate quality control for structural steel fabrication and welding operations.

Responsibilities include:

• Ensure fabrication follows approved engineering drawings and applicable specifications.
• Establish inspection requirements for joint preparation, alignment and fit-up.
• Coordinate verification of welding procedures and applicable welder qualifications.
• Ensure appropriate checks of fillet welds, butt welds and specified weld sizes.
• Monitor visible welding defects including porosity, undercut, overlap, cracks and irregular weld profiles.
• Coordinate dimensional inspection of fabricated assemblies.
• Ensure appropriate control of welding distortion and alignment.
• Review welding-related nonconformities and corrective actions.
• Coordinate with qualified welding inspectors or external inspection providers where required.
• Ensure welding inspection records are maintained according to project requirements.

Knowledge of Welding Procedure Specifications (WPS), welding inspection practices and applicable customer-specified welding standards will be an advantage.

Specialized weld qualification and nondestructive testing activities must be performed by appropriately qualified personnel.

8. In-Process Quality Control (IPQC)

• Establish inspection checkpoints at critical manufacturing stages.
• Develop first-piece inspection and in-process verification requirements.
• Identify critical-to-quality characteristics.
• Implement process inspection plans and check sheets.
• Ensure manufacturing processes remain within approved quality requirements.
• Monitor process deviations and recurring defects.
• Coordinate containment of suspect or nonconforming material.
• Ensure product identification and traceability are maintained.
• Train inspectors in inspection procedures and acceptance criteria.
• Coordinate with Production Managers regarding process corrective actions.
• Support process improvements to prevent defects before final inspection.

9. Final Quality Inspection & Product Release

• Establish final inspection procedures for different product categories.
• Verify finished products against approved customer drawings, specifications and inspection plans.
• Ensure required dimensional, visual, functional and electrical tests are completed.
• Verify inspection records and product identification.
• Ensure nonconforming products are not released without authorized disposition.
• Coordinate final inspection capacity with production schedules.
• Monitor final inspection rejection trends.
• Establish product release procedures according to customer requirements.
• Support packing and dispatch quality verification.
• Maintain required quality documentation and traceability records.

10. Customer Quality, Complaints & Corrective Action

• Act as a primary operational contact for manufacturing quality issues.
• Coordinate investigation of customer complaints and field-reported product defects.
• Establish immediate containment actions when quality problems are reported.
• Lead root cause analysis of significant defects.
• Develop corrective and preventive action plans.
• Use structured problem-solving methods such as 8D, 5 Why and Fishbone analysis.
• Coordinate implementation of corrective actions across affected departments.
• Verify the effectiveness of corrective actions.
• Prepare customer quality reports and responses.
• Monitor repeat complaints and customer rejection trends.
• Support customer visits, inspections and quality audits.

The Quality Manager must take ownership of resolving the causes of quality problems rather than only documenting complaints.

11. Supplier Quality Management & Vendor Development

• Establish supplier quality requirements with Procurement and Engineering.
• Participate in supplier assessment and qualification.
• Review supplier quality performance and incoming rejection trends.
• Develop supplier audit plans where required.
• Coordinate supplier corrective action requests.
• Review recurring material and component defects.
• Support development of alternative suppliers where quality concerns arise.
• Establish appropriate incoming inspection controls based on supplier performance.
• Monitor quality of outsourced machining, fabrication, plating, coating and other processes.
• Coordinate corrective actions to improve supplier consistency.

12. APQP, PPAP, FMEA & Control Plans

Support advanced manufacturing quality planning and customer product approval activities where required.

Responsibilities include:

• Participate in Advanced Product Quality Planning (APQP).
• Coordinate Production Part Approval Process (PPAP) documentation where applicable.
• Support preparation and review of Process Failure Mode and Effects Analysis (PFMEA).
• Develop and maintain manufacturing Control Plans.
• Establish process inspection and verification requirements.
• Participate in manufacturing feasibility reviews.
• Ensure critical product characteristics are identified and controlled.
• Support process validation and sample approval.
• Coordinate manufacturing documentation for new customer programs.
• Ensure approved process changes are properly reviewed and documented.

Experience with automotive quality tools will be useful, particularly for customer programs that require them.

13. Inspection Equipment, Calibration & Measurement Systems

• Identify measuring instruments and testing equipment required by each manufacturing division.
• Establish an appropriate inspection equipment register.
• Develop calibration and verification schedules.
• Coordinate external and internal calibration activities.
• Ensure measuring equipment is suitable for intended use.
• Establish procedures for handling damaged or out-of-calibration equipment.
• Maintain calibration and inspection records.
• Train inspectors in correct measurement techniques.
• Support measurement system analysis (MSA) and gauge R&R studies where applicable.
• Coordinate acquisition of inspection gauges, fixtures and test equipment.

Inspection equipment may include:

• Vernier calipers
• Micrometers
• Height gauges
• Bore gauges
• Angle gauges
• Surface plates
• Crimp-height measuring instruments
• Pull-force testers
• Continuity testers
• Electrical testing equipment
• Coating thickness gauges, where required
• Dedicated dimensional inspection fixtures

14. Root Cause Analysis, CAPA & Problem Solving

• Establish a structured corrective and preventive action system.
• Investigate significant manufacturing nonconformities.
• Identify root causes of repeated defects.
• Apply 5 Why, Fishbone, Pareto and other suitable problem-solving tools.
• Coordinate corrective action ownership with relevant departments.
• Verify effectiveness of implemented actions.
• Maintain nonconformance and CAPA records.
• Monitor overdue quality corrective actions.
• Support mistake-proofing and process improvements.
• Prevent recurring customer and internal quality failures.

15. Quality Audits & Customer Compliance

• Develop internal quality audit schedules.
• Coordinate process audits, product audits and QMS audits.
• Prepare manufacturing departments for customer quality audits.
• Maintain quality documentation and audit evidence.
• Review customer-specific requirements.
• Coordinate closure of audit nonconformities.
• Support certification and surveillance audits.
• Develop corrective actions for systemic quality weaknesses.
• Monitor compliance with approved manufacturing processes.

Knowledge of ISO 9001, relevant customer quality systems and electrical or fabrication standards will be important.

16. RoHS, REACH, UL & Product Compliance Coordination

Some manufacturing products may require compliance with customer, market or regulatory specifications.

Responsibilities include:

• Coordinate quality documentation relating to RoHS and REACH where applicable.
• Review supplier declarations, material certifications and relevant testing records.
• Support customer requirements involving UL-recognized or UL-listed components, where applicable.
• Ensure product markings and manufacturing documentation align with approved requirements.
• Coordinate material or component testing with approved laboratories.
• Maintain traceability of relevant compliance documentation.
• Escalate nonconforming material or compliance concerns to management.
• Work with Engineering, Procurement and external specialists where specialized certification requirements apply.

The Quality Manager will coordinate compliance within the applicable product and certification scope, rather than assume that every manufactured product automatically holds particular approvals.

17. Quality Department Recruitment, Training & Team Management

• Develop quality manpower requirements for different manufacturing departments.
• Recruit and lead Quality Engineers, inspectors and quality supervisors in coordination with HR.
• Establish clear roles and reporting responsibilities.
• Allocate inspection personnel based on production requirements.
• Develop inspector skill matrices.
• Establish training requirements for measurement, inspection and quality documentation.
• Train employees in quality procedures and defect identification.
• Monitor inspection productivity and work quality.
• Develop capable quality team leaders.
• Ensure consistent quality standards across shifts and manufacturing divisions.
• Maintain strong coordination with Production and Engineering.

18. Quality Cost, Scrap & Rework Reduction

• Monitor the cost of poor quality across manufacturing divisions.
• Track internal rejection, rework and customer returns.
• Analyze major causes of material losses.
• Coordinate actions to reduce copper scrap caused by manufacturing defects.
• Monitor sheet metal rejection and rework.
• Identify wiring harness process defects causing material or labour losses.
• Reduce unnecessary inspection repetition and rework.
• Improve manufacturing process capability.
• Coordinate with Production and Finance to quantify quality-related losses.
• Establish measurable cost-of-quality improvement targets.

19. ERP, Quality Documentation & Digital Reporting

• Establish accurate quality records using ERP or approved quality systems.
• Maintain incoming inspection records.
• Track process inspection and final inspection results.
• Record nonconforming materials and dispositions.
• Maintain corrective action records.
• Track supplier quality issues.
• Maintain calibration and audit records.
• Monitor customer complaints and resolution status.
• Support traceability requirements.
• Develop accurate quality dashboards and management reports.
• Coordinate integration of quality records with production and inventory systems.

20. Quality Performance Indicators & Management Reporting

Develop and monitor quality KPIs such as:

• Incoming material rejection
• Supplier defect rate
• First Pass Yield (FPY)
• Defects Per Million (DPM) or DPPM where applicable
• Internal rejection rate
• Rework rate
• Customer rejection rate
• Customer complaints
• Cost of poor quality (COPQ)
• Process audit compliance
• CAPA closure time
• Repeat defects
• Calibration compliance
• Product traceability compliance
• Inspection turnaround time
• Customer audit findings

Prepare regular quality performance reports for the Plant Head and senior management.

Reports should identify significant problems, their root causes, corrective actions and measurable improvement results.

21. Lean Manufacturing, Six Sigma & Continuous Improvement

• Support Lean Manufacturing and structured process-improvement initiatives.
• Apply suitable quality tools to identify and reduce process variation.
• Use Pareto analysis, process data and defect trends to prioritize improvements.
• Support statistical process control (SPC) for suitable manufacturing characteristics.
• Coordinate process capability studies where required.
• Participate in Kaizen and continuous improvement activities.
• Improve error-proofing and manufacturing process controls.
• Reduce recurring defects and variation.
• Promote right-first-time manufacturing.
• Develop a culture of prevention rather than dependence on final inspection.

22. Coordination With Production, Engineering & Management

• Report to the Plant Head or designated senior management.
• Maintain effective coordination with Production Managers across the campus.
• Work with NPD and Engineering on new customer programs.
• Coordinate with Maintenance where equipment conditions affect product quality.
• Work with Procurement regarding supplier quality issues.
• Coordinate with Stores on incoming inspection and nonconforming inventory.
• Work with HR on quality training and skill development.
• Communicate significant quality risks to management.
• Provide independent quality assessments and recommendations.
• Exercise authority to contain or stop nonconforming production according to approved company procedures.

Required Experience

• 10–15 years of manufacturing quality experience, preferably in electrical component manufacturing, wiring harness manufacturing, precision metal fabrication or related industrial manufacturing.
• At least 4 years in a Quality Manager, Quality Assurance Manager, Quality Control Manager, Quality Head or comparable leadership role.
• Practical experience implementing and managing Quality Management Systems.
• Strong knowledge of incoming, in-process and final inspection.
• Experience leading manufacturing quality teams and coordinating with production departments.
• Hands-on knowledge of engineering drawings, inspection methods and quality documentation.
• Experience with customer audits, supplier quality and corrective action management.
• Knowledge of ISO 9001 and relevant manufacturing quality systems.
• Experience with root cause analysis, CAPA, 8D, FMEA and Control Plans.
• Ability to develop quality reporting systems and monitor manufacturing KPIs.
• Strong leadership, communication and technical problem-solving ability.

Greenfield factory setup experience and quality-system implementation from scratch will be strongly preferred.

Strongly Preferred Experience

• Multi-process manufacturing quality management
• Greenfield manufacturing quality department setup
• Wiring harness or cable assembly quality
• Copper busbar or electrical component inspection
• Sheet metal fabrication and precision machining quality
• Structural fabrication and welding quality coordination
• IPC/WHMA-A-620
• ISO 9001
• Customer audits and supplier quality development
• APQP, PPAP and PFMEA
• SPC, MSA and gauge R&R
• RoHS and REACH compliance documentation
• UL-related product documentation and inspection
• ERP-based quality reporting
• Lean Manufacturing and Six Sigma

Direct experience in every manufacturing division is not mandatory. However, the candidate must understand how to establish effective quality systems and manage technically qualified inspection specialists across different manufacturing processes.

Preferred Industry Background

Candidates from the following manufacturing sectors may be considered:

• Wiring Harness and Cable Assembly Manufacturing
• Electrical and Electromechanical Components
• Automotive Component Manufacturing
• Copper Busbar Manufacturing
• Switchgear Component Manufacturing
• Precision Sheet Metal Fabrication
• Industrial Metal Fabrication
• CNC Machining
• Industrial Equipment Manufacturing
• Multi-Process Engineering Manufacturing

Candidates with experience managing quality for several manufacturing processes will be preferred.

Qualifications

• B.E. / B.Tech in Mechanical, Electrical, Electronics, Production, Manufacturing or Industrial Engineering.
• Diploma holders with extensive relevant manufacturing quality and leadership experience may also be considered.
• Additional qualifications or training in ISO 9001, quality auditing, Lean Six Sigma, APQP, PPAP or relevant inspection standards will be an advantage.

Practical quality management capability and demonstrated experience solving manufacturing quality problems are more important than academic qualifications alone.

Ideal Candidate

We are looking for a Quality Manager who can independently establish and manage the quality function for a new multi-factory manufacturing campus.

For example, when the company establishes wiring harness, copper busbar and sheet metal manufacturing divisions, the candidate should be capable of:

• Reviewing customer drawings, specifications and quality requirements.
• Identifying critical manufacturing and inspection characteristics.
• Establishing incoming, in-process and final inspection plans.
• Recommending appropriate measuring instruments and testing equipment.
• Recruiting and training Quality Engineers and inspectors.
• Developing quality procedures and documentation.
• Implementing traceability and nonconforming material controls.
• Establishing calibration and inspection systems.
• Preparing manufacturing departments for customer audits.
• Monitoring rejection, rework and customer complaints.
• Identifying recurring defects and coordinating root cause analysis.
• Developing corrective action plans with Production and Engineering.
• Implementing quality improvement initiatives.
• Building a scalable quality organization capable of supporting future expansion.

We are not looking for someone whose experience is limited to documentation, final inspection or managing an ISO audit calendar.

The ideal candidate should have a practical understanding of manufacturing processes, strong leadership skills, technical inspection knowledge and the ability to prevent quality problems before they reach the customer.

What Success Looks Like

A successful Quality Manager will establish a manufacturing quality system where:

• Quality inspection infrastructure is ready before production begins.
• Incoming, in-process and final inspection procedures are standardized.
• Quality personnel are appropriately trained.
• Manufacturing processes follow approved customer specifications.
• Wiring harness crimping and testing quality are controlled.
• Copper busbar dimensional and surface quality are maintained.
• Sheet metal and fabricated component quality is consistent.
• Supplier nonconformities are identified and resolved.
• Quality records and traceability are reliable.
• Rejection, rework and customer complaints are minimized.
• Customer quality audits are supported effectively.
• Corrective actions are completed and verified.
• Inspection and calibration systems remain effective.
• Quality costs are monitored and reduced.
• The manufacturing campus can expand without sacrificing product quality.

This position offers the opportunity to establish and lead the Quality Assurance and Quality Control function for Celestix Industries' growing multi-factory manufacturing campus in Falna, Rajasthan.