Site Quality Manager - Mechanical & Industrial Construction

Site Quality Manager

Job Summary

Lead all Site Quality Control (QC) and Quality Assurance (QA) functions, ensuring 100% compliance with Field Quality Assurance Plans (FQAP), technical specifications, and statutory requirements (IBR). The goal is zero-defect erection and timely mechanical completion.

Candidate Requirements

Education: Diploma / Bachelor of Engineering in Mechanical Engineering or an equivalent technical degree.

Experience: Total 10-18 years of core experience in Site Quality Management, specifically within power plants, refineries, or heavy industrial construction projects.

Certifications: (Preferred) ASNT Level II in NDT (RT, UT, MPT, LPT), AWS/CSWIP welding inspection, or ISO Lead Auditor certification.

Key Responsibilities

1. Site Quality Control & Inspection

- Execution & Turnaround: Supervise, coordinate, and perform inspections of incoming materials, equipment, and field quality activities within 24 hours of an Inspection Call.

- Adherence to Standards: Ensure all activities align with technical requirements and approved procedures, including FQP (Field Quality Plan), FWS (Field Welding Schedule), HPS, and SOPs.

- System Completion: Conduct Erection Completion Certificate (ECC) checks and perform final walk-downs prior to all Hydro-tests, ensuring the completion of all NDTs (Non-Destructive Testing) and visual checks for pressure parts and piping joints.

- Mechanical Inspections: Attend and oversee inspections for critical mechanical items, including Pressure Parts, Technological Structures, Plates, Forgings, Pressure/Non-pressure piping, Pressure Vessels, EOT Cranes, Wind Boxes, Coal Burner Bodies, Fans, Dampers, and Valves.

2. Quality Assurance & Process Improvement

- Defect Management: Record, analyse, and control the weld defect rate to remain <2%. Provide timely guidance to welders and grinders to achieve sound weld quality and minimize repairs.

- Continuous Improvement: Implement "Mistake Proofing" at the site to prevent defect occurrence and drive Kaizen processes for cost reduction.

- Non-Conformance Management: Identify non-conformities (NCRs) regarding incoming material, transit damages, or erection errors. Initiate NCRs in the Tbits system, follow up with Engineering/HQ for recommendations, and verify closure with the execution team including Root Cause Analysis (RCA) and CAPA (Corrective and Preventive Action).

3. Documentation & Statutory Compliance

- Pre-Planning: Provide required site QA documents and approvals to the site erection team or contractor at least 07 days prior to the start of activities.

- Regulatory Compliance: Obtain necessary statutory compliances, specifically IBR (Indian Boiler Regulations) clearance.

- Reporting: Prepare and submit the Quality MIS to management. Review and issue Inspection Reports (IR) and Inspection Release Notes (IRN).

- Change Management: Supervise and track Design Change Notices (DCN) and Field Change Notices (FCN) at the site, ensuring approval of rectification procedures.

4. Vendor & Contractor Management

- Vendor Selection: Handle Inspection Agency selection, negotiation, and vendor assessment prior to contract finalization.

- Audit & Supervision: Assessment of contractors through verification and controlling processes. Conduct site audits on a fortnightly basis.

- Coordination: Liaison with Third Party Inspection Agencies (TPIA), Manufacturers, Consultants, and Clients. Finalize invoicing and receipt status for inspection agencies.

- Expediting: Monitor progress related to inspections and expedite delayed items to ensure timely delivery.

5. Leadership, Training & Audits

- Team Development: Provide adequate training to enhance the technical knowledge of team members, contractors, and sub-contractors.

- Mentorship: Provide on-site job training for GETs (Graduate Engineer Trainees) and specific training for NDT technicians.

- Auditing: Conduct CFT, Client, and ISO Audits at the site.

- Review Meetings: Hold joint meetings with the client and execution team to address backlogs (specifically analysing NDT backlogs) and create catch-up plans.

Required Competencies

- Technical Knowledge: Deep understanding of WPS (Welding Procedure Specification), PQR (Procedure Qualification Record), WQR, and FWS.

- Technical Expertise: Deep knowledge of Pressure Parts, Heavy Structures, Piping, and Mechanical Equipment (Pumps, Fans, EOT Cranes).

- Standards: Proficiency in IBR, ISO, and site-specific FQAP.

- Analytical Skills: Ability to perform "Why-Why" analysis for corrective and preventive actions.

- Communication: Strong ability to liaise with clients and negotiate with vendors.