Online QC Executive

Job description

Overview

·  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)
·  Root cause and failure analysis for quality defects and implementation of the corrective actions.
Responsibilities

Accountabilities – 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 FLI standards of quality are followed during the production process

·       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:-

a.     Deciding whether blanching is required - Hunter Color Test 

b.     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

c.     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.

d.     Measuring parameters like bulk density, moisture, seasoning and dimension for Non-PC products

·       Taking corrective actions to resolve problems thrown up by the tests

a.     Providing feedback to operators on corrective actions that can be taken for rectifying small problems

b.     Communicating to the shift in-charge the number of pickers needed for the process area on the basis of online checks

c.     Asking the agro department to change the potato lot in case there are no pickers and the number of potato defects are large

d.     Communicating concern areas and corrective actions to the concerned shift in-charge and production manager promptly

e.     Informing the Quality Manager in case test results indicate a crisis situation, who will then conduct a compete trial run of that lot of potato to take an appropriate decision

 

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

a.     Checking after every four hours the percentage of oxygen in the bags - Nitrogen Flushing tests

b.     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 people (quality, engineering, production)

·       Filing these reports on a daily basis by the A-shift quality officer

·       Filling the Weak Link Form to record the results of the oil tests

·       Making a Daily Quality Report for the Quality Manager

·       Recording the weekly housekeeping audit score for every area

·       Updation of reports on the Fourth Shift

·       Ensuring that the operators make quality relevant entries in their log books after every ½ hour

·       Submitting a Quality Control Report QCR to Raw Material Stores within 48 hrs of receipt of material

·       Submitting a Weekly Quality Closing Report on air leakages, warehouse, oil picks etc., weekly air leakage report

·       Providing data for monthly closing report

 

Qualifications

·  ch ( Food Tech)
·  Exposure to food safety systems and ISO systems / 3 to 5 years.
·  Preferably Knowledge of HACCP/AIB and TPM.