Asst Manager - DCA - Quality

: Assistant Manager - Digital Control Automation (Quality)

Position Overview

The Assistant Manager - Digital Control Automation (Quality) will be responsible for overseeing, validating, and optimizing automated control systems to ensure the highest standards of product quality and process compliance. This role bridges the gap between automation engineering and quality assurance, leveraging data-driven insights to minimize process variability, ensure regulatory compliance (such as GAMP5 or FDA 21 CFR Part 11 where applicable), and drive continuous improvement through digital technologies.

Key Responsibilities

1. Quality Assurance & System Validation

• Lead the validation and qualification (IQ/OQ/PQ) of digital control systems, including PLCs, SCADA, DCS, and Manufacturing Execution Systems (MES).
• Ensure all automation architectures and software changes comply with internal quality standards and external regulatory frameworks.
• Establish and enforce Data Integrity protocols for automated data collection, ensuring records are accurate, complete, and tamper-proof.

2. Process Optimization & Digital Control

• Monitor and analyze automated process loops (e.g., PID tuning, sequence controls) to identify anomalies, reduce cycle times, and minimize waste.
• Implement advanced process control (APC) strategies and predictive quality models using real-time machine data.
• Collaborate with production and engineering to troubleshoot complex automation failures affecting product quality.

3. Digitalization & Analytics

• Drive the integration of operational technology (OT) with information technology (IT) systems to enable real-time quality dashboards.

• Utilize Statistical Process Control (SPC) tools and digital twin concepts to predict quality deviations before they occur.
• Lead or support Industry 4.0 initiatives, such as smart sensors deployment and AI-driven quality inspection systems.

4. Compliance, Audit & Change Management

• Manage the Change Control process for all automation software, hardware, and configuration modifications.
• Act as the subject matter expert (SME) during internal and external quality audits for automated systems.
• Investigate quality deviations (CAPA/NCR) linked to automation errors, identifying root causes and implementing permanent fixes.

Job Specifications & Qualifications

Education & Experience

• Education: Bachelors degree in Automation Engineering, Instrumentation & Control, Electrical Engineering, Electronics, or a related technical field.
• Experience: 4 to 7 years of hands-on experience in industrial automation, with at least 2-3 years focused on quality compliance, system validation, or automation quality assurance.

Technical Competencies

• Automation Systems: Strong understanding of PLCs (Siemens, Rockwell, Schneider, etc.), SCADA, DCS, and HMI configurations.
• Quality Standards: Familiarity with ISO 9001. Experience with GAMP5, FDA 21 CFR Part 11, or specific automotive/aerospace quality standards is a massive plus depending on the industry.
• Software & Data: Knowledge of industrial communication protocols (Modbus, OPC UA, Profinet), SQL databases, and data analytics tools (PowerBI, Tableau, or Python/R for data analysis).
• Validation Tools: Experience writing and executing validation protocols, risk assessments (FMEA), and User Requirement Specifications (URS).

Soft Skills

• Strong analytical and problem-solving mindset.
• Excellent cross-functional communication skills (ability to translate complex automation logic into quality/business terms).
• Project management skills with the ability to handle multiple validation/digitalization timelines simultaneously.

Key Performance Indicators (KPIs)

• System Compliance Rate: 100% adherence to validation schedules and data integrity protocols.
• First-Time-Right (FTR): Reduction in quality rejections caused by automation or process control errors.
• Audit Readiness: Zero major non-conformances during internal and external automation quality audits.
• MTTR (Mean Time to Resolve): Minimized downtime during critical automation-related quality incidents.