Senior Engineer - Quality Assurance (Precast Plant)

Job Purpose

To ensure that all precast elements are manufactured in compliance with approved specifications, quality standards, drawings, and customer requirements through effective implementation of quality assurance systems, inspection procedures, and process controls.

Key Responsibilities

Quality Assurance & System Implementation

• Implement and maintain quality assurance systems, procedures, and work instructions across the precast plant.
• Ensure compliance with approved quality plans, ITPs (Inspection & Test Plans), and project specifications.
• Monitor adherence to ISO standards, quality policies, and best manufacturing practices.
• Conduct internal quality audits and facilitate external audits.

Production Quality Control

• Monitor quality at all stages including reinforcement, mold preparation, concrete batching, casting, curing, demolding, finishing, and dispatch.
• Ensure precast elements are produced as per approved shop drawings and quality requirements.
• Verify dimensional accuracy, surface finish, inserts, embedment's, lifting anchors, and reinforcement placement.
• Coordinate stage-wise inspections and approvals.

Concrete & Material Quality

• Monitor testing of raw materials including cement, aggregates, admixtures, and reinforcement steel.
• Ensure compliance with mix design requirements and concrete quality standards.
• Review and maintain concrete testing records such as slump tests, cube tests, and strength reports.
• Analyze test results and initiate corrective actions when required.

Quality Monitoring & Improvement

• Investigate quality issues, customer complaints, and non-conformities.
• Conduct root cause analysis (RCA) and implement corrective and preventive actions (CAPA).
• Identify opportunities for process improvement and defect reduction.
• Monitor rejection rates, rework trends, and quality performance indicators.

Documentation & Reporting

• Maintain quality records, inspection reports, test reports, and quality documentation.
• Prepare daily, weekly, and monthly quality MIS reports.
• Ensure traceability of materials and finished precast products.
• Support project teams during inspections and client audits.

Coordination & Team Management

• Coordinate with Production, Reinforcement, Planning, Maintenance, and Dispatch teams.
• Guide QA/QC Engineers, Inspectors, and Laboratory personnel.
• Conduct quality awareness training programs for plant employees.
• Ensure adherence to quality standards across all departments.

Safety & Compliance

• Ensure quality activities are carried out in compliance with safety regulations.
• Promote quality and safety culture within the precast plant.
• Participate in safety audits and improvement initiatives.

Required Skills

• Precast Concrete Quality Assurance
• Inspection & Test Plan (ITP) Implementation
• Concrete Technology
• Quality Management Systems (QMS)
• Root Cause Analysis (RCA)
• Corrective & Preventive Actions (CAPA)
• Quality Audits
• Dimensional Inspection
• Documentation & MIS Reporting
• Team Handling & Cross-Functional Coordination