Executive Qc

**Auto req ID**: 282864BR

Main Purpose:

- Vertical startup of green field plant with right quality product & building a quality culture in the plant, Stabilization of shift quality operations in new green field plant.
- Ensuring shifts KPIs such as WIP/ Leakages/ Zero red complain
- Ensuring best quality of product and minimum customer complaints through stringent on-line quality control checks and finished product inspection
- Implementing right quality control systems/standards for the processes, physical systems and environment.
- Trouble shooting during online production to minimize wastage and ensure quality.
- Responsible for maintaining GMP, GHK GLP and internal / external audits (HACCP, AIB, Personal Hygiene, Process audit).
- Train and development of quality checkers.
- Ensure quality of potato issued for production.

Scope
- list in priority order the main accountabilities/deliverables of the role, including key measures. These should be clearly the responsibilities of the JOB HOLDER.

**Ensuring that the quality of potatoes issued for production is as per the standard specifications**
- Frying the sample and conducting COOK Test for checking various factors like % of undesirable color, internal defects, greening percentage etc.
- Providing status report to the Agro Department and indicating the number of pickers that will be needed for the particular lot (whose responsibility)
- Deciding whether the lot should be accepted or rejected
- Conducting similar Cook’s Test after every 15 days and whenever required for the potatoes stored in the warehouses under long term storage

**Conducting online quality checks in the process area to ensure that all Pepsico standards of quality are followed during the production process in shifts**
Conducting visual inspection for;
- Ensuring that all key operating parameters of machines are in the specified range
- (Peelers, Fryers, Slicer for thickness average and range, Chip Conveyors, Seasoning Tumbler)
- Ensuring after every hour that the potatoes in the trim and pare area are properly peeled
- Checking slice thickness and free surface moisture after every 4 hours
- Deciding whether to introduce anti-foaming agent in the process
- Recording the dwell time from the operator’s logbook after every 4 hours
- Checking the level of seasoning applied
- Conducting analytical tests for
- Deciding whether blanching is required - Hunter Color Test
- Ensuring optimum utilization of fryer oil
- Conducting 4 hourly checks on oil being used for frying for FFA, OV, PV, foreign materials, taste, odor and specific gravity
- Comparing test results against gold standards oil usage charts
- Deciding the mix of fresh and blended oil to be used for frying operations
- Checking the fried chips after every hour for TPD parameters like PA, percentage oil in the chip, % of soft centered chips, blisters, dark flakes, clusters etc.
- Measuring parameters like bulk density, moisture, seasoning and dimension for Non-PC products

**Taking corrective actions to resolve problems thrown up by the tests**
- Providing feedback to operators on corrective actions that can be taken for rectifying small problems
- Communicating to the shift in-charge the number of pickers needed for the process area on the basis of online checks
- Asking the Agro department to change the potato lot in case there are no pickers and the number of potato defects are large
- Communicating concern areas and corrective actions to the concerned shift in-charge and production manager promptly

**Conducting online quality checks and finished products’ inspection in the packaging area to ensure compliance with Frito Lay standards of quality**
- Ensuring that the Quality Checkers conduct half hourly checks for air leakage and hourly checks for weight, batch printing and air fill
- Conducting analytical tests for
- Checking after every four hours the percentage of oxygen in the bags - Nitrogen Flushing tests
- Conducting random film quality checks on the basis of any special complaints received from the production department
- Communicating concern areas and corrective actions to the concerned operator, shift in-charge and production manager promptly
- Consulting the quality manager in case of criticalities
- Ensuring that the corrective action is implemented

**Monitoring machines in the process and packaging area specifically for their effect on quality and ensuring minimum waste due to machine related factors**
- Calibration of machines like MM55 that detects moisture and % of oil in the chips after they are fried
- Ensuring that the slicer blade is changed after every 1 and ½ hour
- Ensuring that the peeler rollers are changed periodically to avoid under or over peeling
- Maintaining accurate and comprehensive reports for communication to all the people concerned
- Ensuring that the quality checkers make an end of shift report (for air leakage) at the end of every shift and then circulate it amongst the concerned peop