The posting
Department: Quality Control / Quality Assurance
Industry: RO Pressure Vessel / FRP Manufacturing
Reports To: Operations Manager
1. Purpose and Objective:
Quality Engineer is responsible for carrying out incoming material inspection, in-process inspection, material testing, finished-product inspection and product testing and daily reporting for RO Pressure Vessel/Shell manufacturing.
To ensure that every RO Pressure Vessel/Shell is manufactured using approved and traceable materials, inspected at all critical manufacturing stages, tested according to approved procedures, and confirmed to meet specified quality and product requirements before final QC release.
The Quality Engineer shall ensure that materials, manufacturing processes and finished products comply with approved drawings, specifications, work instructions, Inspection & Test Plans (ITP), quality procedures and acceptance criteria. 2. Skill and Knowledge:
The Quality Engineer should have practical knowledge of: FRP/composite manufacturing processes, Filament winding, Glass fiber and resin systems, Basic composite material testing, Resin viscosity and gel-time testing, Barcol hardness testing, Visual inspection of composite defects, Dimensional inspection, Engineering drawings and tolerances, Pressure testing, Material identification and traceability, Inspection & Test Plans (ITP), NCR and rework inspection and Calibration requirements.
Education: Engineering degree / Diploma / Equivalent Technical qualification in Mechanical, Polymer, Composite, Production or equivalent discipline.
Experience: Preferably minimum 4-5 years (Engineer) with mandatory Quality experience in FRP/composite manufacturing, filament winding, pressure vessels, GRP products or similar manufacturing industries.
3. Authority: The Quality Engineer shall have authority to:
- Place incoming materials on HOLD when specifications or documentation do not comply.
- Stop and report a manufacturing activity when a significant quality deviation is observed.
- Identify and segregate non-conforming products.
- Reject inspection stages that do not meet approved acceptance criteria.
- Request re-inspection after corrective action.
- Recommend finished products for QC release after satisfactory inspection and testing.
- Final release authority shall remain with the designated Engineer / QA-QC representative (Operation manager) as defined by the company's Quality Management System.
- Communicate and manage with external authorities (2nd and 3rd party audits) and coordination and Preparation and online handling for FAT visits.
- Preparation of daily, weekly and Monthly reports relevant to QA/QC departments.
Responsibilities: 4. Incoming Material inspection:
- Should be well-conversant in QC laboratory planning, procedures and maintenance.
- Inspect incoming raw materials against Purchase Order, approved specifications, TDS, COA and COC.
- Verify material identification, supplier, batch/lot number, manufacturing date, expiry date and shelf life.
- Check storage conditions and physical conditions of composite raw materials.
- Inspect and verify: Glass fiber roving, Resin systems, Hardener/catalyst and additives, Adhesives and bonding materials, Metallic and non-metallic components, inserts and fittings, End closures and locking components, O-rings and sealing components.
- Ensure proper material identification and traceability.
- Identify, segregate and report damaged, expired or non-conforming materials.
5. Incoming and Process Raw material Testing
Carry out or assist with routine material and composite testing, including qc lab management : Resin viscosity testing, Gel-time testing, Resin/hardener mixing-ratio verification, Cure verification, Barcol hardness testing, Glass/resin content testing where applicable, Loss on Ignition (LOI) testing where applicable, Laminate thickness measurement, Visual examination of composite test samples, Preparation and identification of test coupons/samples, Coordinate samples for third-party laboratory testing when instructed, Record all results in the approved inspection and testing formats. 6. In-Process Inspection / Process control
Perform inspection at defined manufacturing stages.
Set up Inspection: Check liner dimensions and surface condition, verify liner thickness where specified, Inspect for cracks, deformation, scratches or other defects. Verify port/opening locations.
Filament Winding Inspection: Verify approved material batch/lot, checks resin preparation and mixing, monitor resin viscosity and gel time, Verify winding program/reference, Check fiber tension where required, Verify resin impregnation and fiber wet-out, Observe winding pattern and uniformity, Check for dry fibers, gaps, wrinkles and excessive resin, Record applicable process parameters.
Laminate Curing Inspection: Verify curing time and temperature, Record curing parameters where required, Ensure the product is not released for further processing before completion of the specified cure.
Product final release Inspection: Check trimming and machining, labels and identification, process records, inspect port/nozzle preparation, Check bonding/installation of ports and Inspect finished composite surfaces for defects such as Cracks, Delamination, Dry fibers, Air pockets/voids, Resin-rich or resin-starved areas. Fiber exposure and Surface damage.
Dimensional Inspection: Perform and record dimensional inspection according to approved drawings, report any dimension outside the approved tolerance including Overall vessel length, Internal/outer diameter as applicable, Wall/laminate thickness, Port/nozzle dimensions, Port location and orientation, End-opening dimensions, Critical fitting dimensions, End-closure dimensions and fitment.
7. Product Testing & Qualification Support
Responsibilities include preparation, inspection and recording of test samples for: Hydrostatic pressure testing, Leak testing, Burst-pressure testing, Pressure-cycle/fatigue testing, Long-duration pressure testing where applicable, RO membrane/component fitment verification.
During testing, the inspector shall Verify vessel identification and serial number, Confirm calibrated test equipment is being used, Record test pressure and holding time, inspect for leakage, deformation or abnormal conditions, Record observations and results, immediately report failures or abnormalities, Initiate , Maintain supporting records and traceability for Product Qualification Reports. 8. Final Product Inspection and release:
Perform final inspection before QC release, including Visual appearance and workmanship, Overall dimensions, Port configuration, Internal surface condition, External composite surface condition, End-Plate assembly, sealing surfaces, O-rings/seals where applicable, Product identification, Serial number, Nameplate/label, Pressure rating, Material/product traceability, packing condition were included in the inspection scope. Ensure all mandatory inspections, tests and records are completed before recommending the product for release.
9. Non-Conforming Product Identification and Control:
Identify and clearly mark non-conforming materials/products, Segregate rejected material where required, Inform Shift lead /Operations Manager immediately, Raise or assist in preparation of Non-Conformance Reports (NCR), Perform re-inspection after repair/rework, maintain inspection status identification: Accepted / Hold / Rejected.
Do not release non-conforming products without authorized disposition.
10. Inspection & Testing Equipment
Use and maintain Quality lab and inspection instruments such as: Vernier calipers, Micrometers, measuring tapes, Thickness gauges, Go/No-Go gauges, Viscometer, tg tester, LOI furnace, Barcol hardness tester, Weighing scales. Temperature measuring instruments, Pressure gauges/test equipment, Verify the calibration status before use and immediately report expired, damaged or inaccurate measuring equipment.
11. Maintain Quality Documentation:
Maintain accurate and traceable records for: Incoming Material Inspection Reports, Material Testing Reports, Resin viscosity and gel-time records, In-Process Inspection Reports, Filament Winding Inspection Records, Curing Records, Dimensional Inspection Reports, Hydrostatic Test Reports, Burst/Qualification Test Records, Final Inspection Reports/Rework Inspection Records, Material traceability records, Calibration verification records in line with the ISO 9001 Standard requirements. Maintain FAT visit documentation. All inspection records shall be clear, signed/identified and traceable to the relevant material batch and finished vessel serial number.
12. Key Performance Areas
Ensure Accuracy and completeness of inspection records of Incoming material inspection compliance, In-process inspection completion rate, First-pass inspection acceptance, Reduction of inspection escapes, Timely identification of defects, Material and product traceability compliance, Calibration compliance, Timely completion of inspection/testing and inspection closure of internal and external management audits non conformances and Zero release of products without mandatory inspection/testing.
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