Department: Quality Assurance – Coke Oven Division
Reports to: Head of Operations / Plant Head

Job Purpose:

To lead the quality assurance and quality control functions of the Coke Oven Plant, ensuring high-quality coke production that meets internal metallurgical specifications and customer requirements. The role involves laboratory management, process control, and coordination with cross-functional teams using SAP systems in a heavy industrial environment.

Key Responsibilities:

1. Quality Management of Coke Oven Operations

• Oversee quality systems for all stages of coke oven operation including coal blending, coking, pushing, quenching, and screening.
• Ensure compliance with metallurgical coke specifications (ash, VM, moisture, CSR/CRI, M40/M10).
• Continuously improve product quality through process audits, statistical process control, and preventive actions.

2. Laboratory & Testing Operations

• Manage the coke oven laboratory including proximate analysis, ultimate analysis, and mechanical strength tests.
• Ensure the use, calibration, and maintenance of advanced lab instruments.
• Validate test results and ensure traceability and accuracy of lab reports through SAP-based data logging.

3. SAP Integration & Data Management

• Utilize SAP QM (Quality Management) module for test recording, material quality status updates, and quality notifications.
• Integrate quality control processes with production, procurement, and logistics modules within SAP.
• Ensure real-time quality data tracking, reporting, and digital documentation through SAP.

4. Process Optimization & Root Cause Analysis

• Conduct regular root cause analysis (RCA) for quality deviations and implement CAPA using tools like 5 Whys, Fishbone Diagrams, and FMEA.
• Lead process improvement initiatives like Six Sigma, 5S, and Kaizen.
• Monitor KPIs related to coke quality and lab performance; drive cost-effective improvements.

5. Regulatory Compliance & Audits

• Ensure adherence to ISO 9001, 14001, and 45001 standards and manage audit readiness.
• Maintain documentation and operational controls to comply with environmental and safety regulations (including KSPCB guidelines).
• Lead and close out internal and external audits related to quality and process standards.

6. Team Leadership

• Supervise and mentor lab analysts, quality inspectors, and quality engineers.
• Conduct regular training programs on quality tools, testing standards, and SAP QM module usage.
• Foster a culture of continuous quality improvement and team accountability.

7. Cross-Functional Collaboration

• Liaise with production, coal handling, maintenance, and EHS teams to ensure alignment on quality goals.
• Support procurement with supplier quality assessments and incoming material inspections.

Required Skills & Competencies:

• Deep knowledge of coke oven processes (by-product and non-recovery), coal chemistry, and coke testing protocols.
• Proficient in SAP QM, MM, and PP modules – especially in inspection planning, test result recording, and material disposition.
• Strong analytical and problem-solving skills using quality tools (SPC, MSA, FMEA, Pareto).
• Solid understanding of heavy industry practices, including safety and environmental compliance in steel or coke oven plants.
• Effective communication and leadership abilities to work in a cross-functional and unionized environment.

Educational Qualifications:

• B.E./B.Tech in Chemical Engineering, Metallurgy, Mechanical, or Industrial Chemistry
• Certifications in Quality Management Systems, ISO Lead Auditor, or Six Sigma (preferred)

Experience:

• 10–15 years of relevant experience in quality assurance in heavy industries such as steel, coke oven, or metallurgical plants.
• At least 5 years in a managerial or supervisory capacity.
• Hands-on experience in SAP Quality Management and working in a digitally integrated production environment.

Desirable Attributes:

• Background in integrated steel plants or coke oven battery operations (Stamp/Top Charging).
• Exposure to ESG standards, sustainability initiatives, and carbon reduction practices in heavy industry.
• Familiarity with industry 4.0 tools for digital quality control and predictive analytics.

Key Responsibilities:

1. Quality Management of Coke Oven Operations

• Oversee quality systems for all stages of coke oven operation including coal blending, coking, pushing, quenching, and screening.
• Ensure compliance with metallurgical coke specifications (ash, VM, moisture, CSR/CRI, M40/M10).
• Continuously improve product quality through process audits, statistical process control, and preventive actions.

2. Laboratory & Testing Operations

• Manage the coke oven laboratory including proximate analysis, ultimate analysis, and mechanical strength tests.
• Ensure the use, calibration, and maintenance of advanced lab instruments.
• Validate test results and ensure traceability and accuracy of lab reports through SAP-based data logging.

3. SAP Integration & Data Management

• Utilize SAP QM (Quality Management) module for test recording, material quality status updates, and quality notifications.
• Integrate quality control processes with production, procurement, and logistics modules within SAP.
• Ensure real-time quality data tracking, reporting, and digital documentation through SAP.

4. Process Optimization & Root Cause Analysis

• Conduct regular root cause analysis (RCA) for quality deviations and implement CAPA using tools like 5 Whys, Fishbone Diagrams, and FMEA.
• Lead process improvement initiatives like Six Sigma, 5S, and Kaizen.
• Monitor KPIs related to coke quality and lab performance; drive cost-effective improvements.

5. Regulatory Compliance & Audits

• Ensure adherence to ISO 9001, 14001, and 45001 standards and manage audit readiness.
• Maintain documentation and operational controls to comply with environmental and safety regulations (including KSPCB guidelines).
• Lead and close out internal and external audits related to quality and process standards.

6. Team Leadership

• Supervise and mentor lab analysts, quality inspectors, and quality engineers.
• Conduct regular training programs on quality tools, testing standards, and SAP QM module usage.
• Foster a culture of continuous quality improvement and team accountability.

7. Cross-Functional Collaboration

• Liaise with production, coal handling, maintenance, and EHS teams to ensure alignment on quality goals.
• Support procurement with supplier quality assessments and incoming material inspections.