Quality Control Engineer

Job Description: Quality Engineer – Moulding Department

Department: Quality / Moulding

Designation: Quality Engineer – Moulding

Reporting To: QA Head / Production Head

Location: 525, Udyog Kendra 2, UPSIDC Site A, Ecotech III, Greater Noida, Habibpur, Uttar Pradesh 201306

Job Purpose

The Quality Engineer – Moulding Department is responsible for ensuring that all moulded products are manufactured as per approved quality standards, customer specifications, drawings, and internal process requirements. The role includes inspection, process control, defect analysis, documentation, corrective action, and continuous improvement in the moulding process.

Key Responsibilities

1. In-Process Quality Inspection

The Quality Engineer shall inspect moulded components during production to ensure that products meet the required specifications.

Key checks include:

• Dimensions of moulded parts
• Weight of components
• Visual appearance
• Flash, burr, short moulding, sink marks, cracks, warpage
• Colour matching
• Shrinkage
• Fitment with related parts
• Surface finish
• Deformation or damage

2. First Piece Approval

The Quality Engineer is responsible for checking and approving the first piece before starting mass production.

First piece inspection includes:

• Product dimension verification
• Weight verification
• Visual inspection
• Fitment checking
• Comparison with approved sample or drawing
• Machine setting verification
• Recording approval in the First Piece Inspection Report

Production should continue only after first piece approval.

3. Routine Quality Monitoring

The Quality Engineer shall conduct periodic inspections during running production.

Typical inspection frequency:

• Every hour
• After machine setting change
• After mould change
• After material change
• After any breakdown or restart

Inspection results must be recorded properly.

4. Rejection Control

The Quality Engineer is responsible for monitoring and controlling rejection in the moulding department.

Common moulding defects include:

• Short moulding
• Flash
• Burning marks
• Sink marks
• Warpage
• Colour variation
• Black spots
• Cracks
• Flow marks
• Shrinkage
• Dimensional variation
• Poor fitment

The engineer must identify the root cause and coordinate with production for correction.

5. Process Control

The Quality Engineer shall monitor important moulding process parameters such as:

• Barrel temperature
• Mould temperature
• Injection pressure
• Holding pressure
• Cooling time
• Cycle time
• Material drying condition
• Machine setting
• Mould condition

Any abnormality must be reported immediately.

6. Documentation and Records

The Quality Engineer must maintain all quality-related records properly.

Important records include:

• First Piece Inspection Report
• In-Process Inspection Report
• Final Inspection Report
• Rejection Report
• Defect Analysis Report
• CAPA Report
• Customer Complaint Report
• Daily Quality Summary
• Calibration records of measuring instruments

7. Corrective and Preventive Action

The Quality Engineer shall support root cause analysis and CAPA for internal rejection and customer complaints.

Tools used:

• 5 Why Analysis
• Fishbone Diagram
• CAPA
• Pareto Analysis
• Rejection Trend Analysis

The engineer must ensure that corrective actions are implemented and verified.

8. Final Inspection

Before dispatch or transfer to the next process, the Quality Engineer shall ensure final product quality.

Final inspection includes:

• Visual inspection
• Dimension check
• Weight check
• Packing condition
• Label verification
• Quantity verification
• Customer specification verification

9. Handling of Non-Conforming Products

The Quality Engineer shall identify, segregate, and label rejected or doubtful material.

Non-conforming material must be marked as:

• Accepted
• Rejected
• Hold
• Rework
• Customer approval required

No defective material should move to the next process without approval.

10. Coordination with Other Departments

The Quality Engineer shall coordinate with:

• Production team
• Mould maintenance team
• Tool room
• Store department
• Dispatch team
• QA Head
• Customer quality team, if required

Required Skills

The candidate should have knowledge of:

• Injection moulding process
• Plastic material behavior
• Dimensional inspection
• Vernier caliper, micrometer, height gauge usage
• Defect identification
• Root cause analysis
• CAPA preparation
• Quality documentation
• Basic Excel reporting
• Customer quality requirements

Measuring Instruments Knowledge

The Quality Engineer should be able to use:

• Vernier caliper
• Micrometer
• Height gauge
• Weighing scale
• Go / No-Go gauge
• Pin gauge
• Radius gauge
• Thickness gauge
• Color matching sample
• Measuring tape

Daily Responsibilities

• Check first piece approval before production starts
• Inspect running production as per frequency
• Record inspection results
• Monitor rejection percentage
• Inform production team about defects immediately
• Stop production in case of major quality issue
• Segregate defective material
• Prepare daily quality report
• Verify rework material
• Maintain quality records

Authority

The Quality Engineer has authority to:

• Hold defective material
• Stop production in case of major quality defect
• Reject non-conforming products
• Approve first piece after inspection
• Escalate repeated quality issues to QA Head
• Ask production team for correction in machine setting or process

Qualification

Minimum Qualification: Diploma / B.Tech in Mechanical, Plastic Technology, Production, or related field

Experience: 1–3 years in moulding quality inspection preferred

Industry: Plastic moulding / packaging / manufacturing

Key Performance Indicators

• Reduction in moulding rejection percentage
• First piece approval accuracy
• Customer complaint reduction
• Timely completion of inspection reports
• CAPA closure on time
• Reduction in repeated defects
• Proper segregation of rejected material
• Compliance with quality standards