Associate Manager - Quality Assurance

Key Responsibilities A. Woven Fabric Quality Assurance • Monitor and improve fabric quality at greige, processing, and finished fabric stages. • Ensure compliance with customer specifications, approved standards, and quality parameters. • Analyze woven fabric defects such as missing ends, missing picks, broken ends, broken picks, reed marks, weft bars, slubs, stains, holes, selvedge defects, and shade variations where applicable. • Review fabric inspection reports using the 4-point system or applicable customer inspection standards. • Monitor fabric rejection, downgrade, rework, and customer complaint trends. B. Continuous Improvement • Identify recurring quality issues and implement improvement projects to reduce defects and fabric rejection. • Apply continuous improvement methodologies such as PDCA, Kaizen, 5 Why Analysis, Fishbone Diagram, Pareto Analysis, and Root Cause Analysis. • Establish measurable quality improvement targets and monitor progress against KPIs. • Reduce internal quality costs, rework, wastage, and customer claims. • Standardize successful improvements through updated SOPs, work instructions, and quality checkpoints. C. Process Quality Improvement • Work closely with weaving, warping, sizing, drawing-in, inspection, and finishing teams to eliminate process-related defects. • Investigate machine-related and process-related quality problems, including loom settings, warp tension, weft insertion, yarn quality, sizing performance, and fabric construction. • Coordinate with production and maintenance teams to prevent recurring defects and improve process capability. • Conduct process audits and verify the effectiveness of corrective actions. D. Quality Data Analysis and Reporting • Prepare daily, weekly, and monthly quality performance reports. • Track key performance indicators, including:• First-pass yield (FPY) • Fabric defect rate and defects per 100 metres • Rejection and downgrade percentage • Customer complaint rate • Rework and wastage percentage • CAPA closure and recurrence rates • Use Excel, dashboards, Pareto charts, and trend analysis to identify improvement opportunities. • Present improvement results and action plans during quality review meetings. E. Customer Quality and Compliance • Investigate customer complaints related to woven fabric quality and coordinate corrective actions. • Support customer audits, internal audits, and supplier quality assessments. • Ensure traceability of fabric lots, inspection records, and corrective action documentation. • Verify that implemented solutions prevent recurrence and meet customer requirements. F. Training and Team Development • Train quality inspectors and production personnel on fabric defect identification, inspection methods, and quality standards. • Promote a quality-at-source culture and encourage employee participation in Kaizen activities. • Conduct periodic awareness sessions on defect prevention and standard operating procedures. Key Performance Indicators (KPIs) • Reduction in woven fabric defect rate. • Reduction in fabric rejection and downgrade percentage. • Improvement in first-pass yield. • Reduction in customer complaints and claims. • Reduction in rework, wastage, and cost of poor quality. • Timely closure and effectiveness of CAPA. • Improvement project completion rate and verified cost savings. • Compliance with inspection standards and process audit requirements. Educational Qualifications • Diploma or Bachelor’s degree in Textile Technology, Textile Engineering, or a related discipline. • Additional training in Quality Management, Six Sigma, Lean Manufacturing, or Continuous Improvement is preferred. Required Skills and Competencies • Strong knowledge of woven fabric construction, weaving processes, and textile defects. • Expertise in root cause analysis and corrective/preventive action. • Knowledge of fabric inspection systems, particularly the 4-point system. • Working knowledge of ISO 9001 quality management principles. • Proficiency in MS Excel, quality reporting, and data analysis. • Strong analytical, problem-solving, communication, and coordination skills. • Ability to lead cross-functional improvement projects and achieve measurable results. Expected Outcomes • Consistent improvement in woven fabric quality. • Lower fabric rejection, rework, and customer complaints. • Improved process control and defect prevention. • Better coordination between production and quality teams. • Sustainable, data-driven continuous improvement across the fabric manufacturing process. Department: Quality Assurance Experience: 2 - 5 Years