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. Experience: 24+ years Department: Arvind Shirting-Wovens Fabric