Plant In-Charge Quality - Pipodara

Job Overview

This role involves overseeing quality assurance and quality control protocols for concrete products at the plant, facilitating the promotion of Vacuum Assisted Casting (VAC) techniques, and optimizing concrete mix formulations to meet customer needs.

Context and Challenges

The Ready-Mix Concrete (RMC) sector is highly fragmented and strongly competitive, with both organized and local players. As a significant RMC entity, maintaining superior service quality and product excellence is critical for sustaining profit margins. Infrastructure development growth enables new commercial and dedicated plants, demanding efficient resource utilization and maximal production capacity at the plant level. Employee focus on key responsibilities and accountability is essential to achieve operational efficiency and profitability.

Primary Responsibilities

• Lead demonstrations of VAC products to clients, explaining features and benefits.
• Address customer complaints related to issues such as cracking, slump, pumping difficulties, and cube failures, implementing corrective and preventive solutions based on site evaluations.
• Conduct periodic customer and site visits to solicit feedback and identify improvement areas.
• Provide clients with detailed mix design computations and physical and chemical analyses of raw materials upon request.
• Maintain quality control laboratories, ensuring proper upkeeping, product displays, and availability of relevant Bureau of Indian Standards (BIS) codes.
• Ensure timely calibration of instruments prior to due dates to maintain testing accuracy.
• Perform physical stock audits and reconcile inventory records.
• Maintain quality documentation within LabSys software in compliance with Quality Council of India (QCI) and ISO standards, including calibration records for all testing devices.
• Prepare, consolidate, and analyze plant operational plans and budgets.
• Compile plant-level mix and competitor data to support product development activities.
• Design mix formulations tailored to customer requirements.
• Test concrete cubes to confirm adherence to quality standards, conduct statistical analysis of strength results, and monitor product performance.
• Run trials for VAC products to evaluate functional parameters.
• Assess quality of incoming raw materials, rejecting those not meeting specified standards.
• Collaborate with third-party testing agencies for concrete cube testing as necessary.
• Conduct trials for dosing and performance evaluation of various admixtures, special materials, and routine products to ensure quality compliance.
• Ensure timely execution of VAC product orders per plant according to specifications.
• Monitor batch quality by tracking standard deviation to keep concrete within allowable quality limits and implement corrective actions as required.
• Ensure proper concrete workability and cohesiveness both at the plant and on-site during pouring.
• Apply moisture corrections during production processes.
• Supervise the correct doses of admixtures used at batching plants during production.