Quality Assurance Auditor (Shift) Job in Kenya

Sheer Logic Management Consultants is seeking to engage a dynamic individual for a Quality Assurance Auditor (Shift) position for one of our clients.

Reports To: QA & CI Manager

Context / Scope: Central Glass Industries is fully acquired by CONSOL Glass SA and is a major glass container manufacturer in East and Central Africa and currently operating at full capacity of 130 ton due to economic upturn in the region and expansion into new geographies.

The quality assurance department provides quality assurance services and ensures that a clean and hygienic working environment is maintained to ensure products meet customer requirements and consequently company’s profit.

The job holder works closely with the Quality Assurance & CI Manager for the continued operations within the QA Department. He / She works closely with the Physical Lab Analyst, Final Inspectors and Post Production Controllers.

Market Complexity: Operates in a very competitive glass market environment and to-day’s customer is more quality conscious and demands total satisfaction. This demands a consistent production of quality glass containers that meet both customer specifications and is price competitive.

Due to influx of imported high quality glass containers that would affect sales of our products there is need to consistently improve on quality of our glass containers to maintain our market share.

It is critical that we obtain high quality raw materials that are readily available locally to ensure production of high quality glass containers through liaising with our suppliers.

Leadership Responsibilities: The job holder works on Shift basis and is the overall shift team leader of the Quality Assurance Activities in the QA department (Physical Lab and the QA Inspection floor). The shift QA Auditor will be responsible for verification of bottle dimensions, strengths and related on-shift tests.

The Shift QA Auditor will be responsible for completing all relevant reports at the end of his shift.

Purpose of Role: To ensure that Product inspection and testing are carried out as per the established quality plans so as to ensure that the products released from the Production process meets customer specifications

Top Accountabilities

QA LAB – Lab supervision & general function.

Ensure QA Lab functions in an effective and disciplined manner.

  • Ensure all relevant checks are done at stipulated intervals.
  • Ensure continuous and accurate feedback to shift production unit.
  • Identify and action labour problems. This includes discipline, timekeeping and labour shortage in lab.
  • Ensure follow up is done on all non-conforming issues.
  • Check and verify all relevant test results before shift end. Action problems immediately.
  • Make sure filing of quality records are done properly to standard.
  • Ensure / verify that all relevant quality checks are done according to procedure.
  • Ensure customer requirements are adhered to.
  • Ensure good housekeeping in QA lab at all times.

PROCESS AUDIT – Routine process audit

Effective routine process audit covering hot end, lehr inspection, cold end automatic inspection, basic warehandling, palletising, pack quality and shroud quality.

  • Perform process audit as per current procedures and S.O.P’s.
  • Ensure timeous feedback and corrective action on all non-conforming issues.
  • Ensure proper inspection at hot end.
  • Ensure all relevant hot end paperwork is done.
  • Ensure proper warehandling and mass control at hot end.
  • Verify correctness of all go – no go gauges at hot end and cold end.
  • Ensure proper lehr inspection and defect tracing is done at cold end.
  • Verify calibration status of cold end inspection equipment.
  • Monitor warehandling for possible risk to customer.
  • Monitor and minimize defect running time and defect frequency per defect / mould.
  • Ensure / verify pack for correctness at palletizer.
  • Ensure / verify correctness / presence of ink-jet coding.
  • Ensure proper operation of inverters for wide mouth ware.
  • Check palletizer handling / operation for possible risk to customer, i.e. dropped bottles, chip finishes etc.
  • Verify correctness of label.
  • Verify shroud application quality.

PRODUCT AUDIT – One set per shift per line. (This includes the MCB Test.)

Routine thermal shock test

  • Perform product audit as per current procedures and S.O.P.’s.
  • Ensure compliance to Q.C. limit samples.
  • Adhere to withdrawal rules.
  • Ensure timeous feedback to implement effective prevention.
  • Ensure proper record keeping in general.
  • Ensure quality status as per procedure.
  • Eliminate the possibility of mass withdrawals through effective communication, correction and prevention.

Forced audit on packed ware.

  • Ensure timeous follow up on suspect ware.
  • Ensure risk is known from previous shift.
  • Communicate risk on suspect ware to next crew / shift.

CAPACITY – One set per shift per line. (This includes the MCB Test.)

Routine mould set capacity.

  • Perform standard capacity test as per procedure on full mould set once per shift.
  • Check set for known defects before test.
  • Report defect via NCR to Supervisor
  • Action all failures as per procedure.

NOTE:

> Test to be physically performed whenever Auditor is responsible for 2 lines only.

> Wherever Auditor is responsible for 3 lines this test may be performed by a Q.C. Clerk assigned to it. In this case the Auditor for these specific lines is responsible for data interpretation and total decision making.

THERMAL SHOCK – One set per shift per line.

Routine thermal shock test

  • Perform standard thermal shock test on production bottles as per procedure.
  • Check bottles for all known defects before test.
  • Action all defects via Supervisor and N.C.R.
  • Action thermal shock failures as per procedure.

NOTE:

Test to be physically performed whenever Auditor is responsible for 2 lines only.

Wherever Auditor is responsible for 3 lines this test may be performed by a Q.C. Clerk assigned to it. In this case the Auditor for these specific lines is responsible for data interpretation and total decision making.

SHADOWGRAPH One set per shift per line.

Routine standard shadowgraph checks.

  • Perform shadowgraph test per line per shift.
  • Utilize latest shadowgraph spec. drawing.
  • Perform test according to set limits on drawing.
  • Action all failures or borderline cases as per procedure.
  • Record all results as prescribed.
  • Report equipment problems to supervisor.

NOTE:

Test to be physically performed whenever Auditor is responsible for 2 lines only.

> Wherever Auditor is responsible for 3 lines this test may be performed by a Q.C. Clerk assigned to it. In this case the Auditor for these specific lines is responsible for data interpretation and total decision making.

ANNEALING – Three bottles every 2 hours.

Routine annealing check.

  • Perform standard annealing check on production bottles as per procedure.
  • Check bottles for all known defects during test.
  • Action all defects via supervisor and NCR.
  • Action annealing failures as per procedure.
  • Record all results.

NOTE:

Test to be physically performed whenever Auditor is responsible for 2 lines only.

Wherever Auditor is responsible for 3 lines this test may be performed by a Q.C. Clerk assigned to it. In this case the Auditor for these specific lines is responsible for data interpretation and total decision making.

COATING – Finish, three bottles per 2 hours.

Routine coating checks.

  • Perform standard coating test on production bottles as per procedure.
  • Check bottles for all known defects during test.
  • Action all defects via supervisor and NCR.
  • Action coating failures as per procedure.
  • Record all results.

NOTE:

Test to be physically performed whenever Auditor is responsible for 2 lines only.

> Wherever Auditor is responsible for 3 lines this test may be performed by a Q.C. Clerk assigned to it. In this case the Auditor for these specific lines is responsible for data interpretation and total decision making.

COMMUNICATION – Inter-departmental communication

Effective clear, accurate and timeous communication within Q.A

  • Ensure shift log is done in a proper manner reflecting accurate and factual information.
  • Telephonically contact QA Manager and/or QA Superintendent when / if necessary.
  • Make sure accurate representative samples are retained when necessary.
  • Make sure critical aspects are properly highlighted to relevant staff.

Cross functional communication – Effective, clear accurate and timeous communication with other department

  • Ensure effective communication to and with Shift Manager on risks, suspect ware and withdrawals.
  • Ensure effective communication with hot end and line supervisor on risks and withdrawals.
  • Communicate effectiveness of corrective action to all relevant people.

HOUSEKEEPING – General housekeeping.

Adherence to current housekeeping standards.

  • Ensure housekeeping at all times on all inspection stations.
  • Ensure good housekeeping at all times in Q.C. Lab

MANPOWER – Manpower management.

Application of manpower affecting quality function.

  • Ensure only capable people perform lehr inspection tasks.
  • Ensure labour problems/shortage in Q.C. Lab are solved effectively.
  • Maintain disciplinary code.
  • Identify and communicate training needs regarding quality activities.
  • Action / follow up / initiate action / on all staff related problems (shift).
  • Adhere to dress code. Ensure compliance by lab staff.

GENERAL – General issues

Note, maintain, and adhere to, all general company / working related issues / requirements.

  • Respect the Consol tenets.
  • Observe communication through company notice boards and other related media.
  • Adhere to company rules, values and objectives in general.
  • Carry out any reasonable request by management.
  • Adhere to dress and disciplinary codes.
  • At all times adhere and practice SAFETY and ENVIRONMENTAL rules within the company.
  • Record all held ware and follow up resorts.
  • Assist with quality follow-up on suspect pallets when required by supervisor.
  • Complete all relevant documentation and reports in full.
  • Action suspect situations immediately.
  • Adhere to all standard safety rules / requirements (HACCP and PRP).
  • Adhere to basic shift discipline procedures.
  • Do routine mass checks at hot end 2 hourly and record results.
  • Issue NCR if not working to scale mass set-out.
  • Keep workplace neat and clean.
  • Monitor all palletized ware for shrouding efficiencies.
  • Monitor gauges on line.

REASONABLE OPERATIONAL REQUIREMENTS

  • It is a requirement to execute all reasonable requests from management even if not directly related to this function.

Qualifications

  • A Bachelors degree in Chemistry or Chemical Engineering.
  • Trained in Management Systems (QMS, OHSAS, EMS & FSMS) including internal audit for the same.

Experience

  • Minimum of three (3) years working in a Quality Assurance function in a busy manufacturing environment.

How to Apply:

If you believe your career objectives match this exciting position, please forward your application and detailed C.V stating your current position, remuneration, contact details by 6th March 2018 to the Sheer Logic Management Consultants E- Mail: recruitment@sheerlogic.co.ke clearly marking – “Quality Assurance – Audit”.

Only short-listed candidates will be contacted.

Our Client is an Equal opportunity employer.


Biology Chemisty Sciences, Audit and Quality Assurance
Updated: March 2, 2018 — 7:10 pm