PGP Glass - Deputy General Manager/General Manager - Quality

Location: Vadodara, Gujarat.

Experience: 15 years.

Key Responsibilities:

Quality Systems Implementation & Compliance:

• Implementation and maintenance of procedures related to:

• 1. Identification and traceability of finished products.
• 2. Inspection and testing of finished bottles and vials.
• 3. Inspection and test status control.
• 4. Control of non-conforming products.
• 5. Corrective and Preventive Action (CAPA).
• 6. Handling, storage, packaging, preservation, and delivery of finished bottles and vials.
• 7. Review and continuous improvement of the Quality Management System.

• Ensure full compliance with:

• 1. GMP (Good Manufacturing Practices).
• 2. QMS (Quality Management System).
• 3. ENMS (Energy Management System).
• 4. FSMS (Food Safety Management System, if applicable).
• 5. ISO standards.
• 6. EMS (Environmental Management System).
• 7. OHSAS / Occupational Health & Safety standards.

• Lead internal and external audits.
• Maintain documentation as per regulatory requirements.

Raw Material & Batch Quality Control:

• Inspection and approval of:

• 1. Silica sand.
• 2. Soda ash.
• 3. Limestone.
• 4. Dolomite.
• 5. Cullet.
• 6. Additives and colorants.

• Monitor batch composition accuracy and homogeneity.
• Conduct chemical analysis and maintain test records.
• Coordinate vendor quality audits and supplier improvement programs.

In-Process & Cold End Quality Control:

• Overall Responsibility of Cold End Department.
• Supervise inspection activities at Cold End.
• Monitor and control:

• 1. Dimensional accuracy.
• 2. Weight consistency.
• 3. Wall thickness.
• 4. Finish and neck dimensions.
• 5. Visual defects (checks, cracks, stones, blisters, inclusions, seeds, scratches).

• Ensure proper functioning of inspection machines:

• 1. Automatic inspection machines.
• 2. Camera-based defect detection systems.
• 3. Leak testing equipment.
• 4. Vertical load testing machines.
• 5. Thermal shock testing systems.

• Monitor annealing lehr temperature profile and stress levels.
• Conduct strain testing using polariscopes.
• Maintain AQL levels and rejection analysis.

Finished Product Inspection & Testing:

• Ensure proper identification and traceability of finished bottles and vials.
• Maintain inspection and test status of each batch.
• Conduct:

• 1. Compression testing.
• 2. Internal pressure testing.
• 3. Impact resistance testing.
• 4. Thermal shock resistance testing.

• Approve/reject finished goods before dispatch.
• Ensure proper packaging, preservation, and delivery as per customer and regulatory requirements.

Control of Non-Conforming Products:

• Identify and segregate non-conforming products.
• Ensure proper labeling and documentation.
• Conduct Root Cause Analysis (RCA).
• Implement Corrective and Preventive Actions (CAPA).
• Monitor effectiveness of corrective measures.

Customer Complaint Handling (B+C Sort):

• Overall responsibility for customer complaint resolution.
• Handle B+C Sort activities effectively.
• Conduct complaint investigation and defect analysis.
• Coordinate sorting, inspection, and corrective actions.
• Maintain complaint trend analysis reports.
• Reduce repeat complaints through systemic improvement.

Calibration & Laboratory Management:

• Ensure calibration of inspection and measuring instruments.
• Maintain calibration records and schedules.
• Oversee laboratory testing activities.
• Ensure all instruments comply with standard requirements.
• Maintain documentation and test reports.

Training & Records Management:

• Identify training needs for department members.
• Provide and maintain records of training.
• Conduct regular skill development and GMP awareness sessions.
• Ensure competency evaluation of inspectors and technicians.

Process Improvement & Cost of Quality:

• Monitor:

• 1. Rejection %.
• 2. Customer complaint rate.
• 3. First-pass yield.
• 4. Cost of poor quality (COPQ).

• Drive Six Sigma / Lean initiatives.
• Improve production yield and reduce breakage.