Plant Quality Assurance Manager, Faisalabad

Title: Plant Quality Assurance Manager, Rakh Canal Plant

Location: Faisalabad

Reports To: Pakistan Quality Assurance Manager

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The Plant QA Manager is responsible for leading the plant quality functions and personnel to safely, responsibly, consistently and cost effectively test and produce products that meet all applicable government, customer and company expectations. The incumbent will ensure the plant execution of the IPS Quality Pillar delivers the continuous improvement of results for: in-process rework/downgrades; first pass compliance (FPC) metrics; customer complaints; internal/external audit results. 

Core Responsibilities:

Leadership and Behavior

• Through the Leadership Competencies of META5, lead all aspects of plant Quality Assurance (QA) and Quality Control (QC)
• Provide leadership and guidance to the quality teams to understand, implement, and sustain the IPS pillars to achieve goals and operate within the annual department budget.
• Ensure IPS Safety Pillar requirements are known and in place for the quality team. Drive quality EHSS management and achieve all EHSS targets and ensure minimum recordable incidents.
• Ensure IPS HR pillar requirements are known and in place for the quality team. Provide leadership in developing, coaching, and supporting the plant Quality team to inspire potential and deliver strong performance. Build Great Talents.

Cultural Improvement

• Improve and develop the plant quality culture. Coordinate Quality Month activities and communication for the plant. 
• Ensure plant employees receive training to comply with IPS quality pillar. Verify compliance of internal and external training to meet regulatory and customer requirements.
• Ensure the IPS Reliability Pillar requirements are known and in place for the quality team.
• Ensure the IPS Management Pillar requirements are known and in place for the quality team.
• Manage quality communication to all levels of the plant organization.
• As the plant quality leader and owner of the IPS Quality Pillar:
  • Cascade quality strategy to the site leadership team.
  • Ensure that all work activities of plant employees are performed with attention to the highest standards of quality, food safety, regulatory compliance with all Ingredion, certification body, customer, or legal requirements…doing things right the first time.
  • Track & monitor plant quality performance. Ensure non-conformances/non-compliances are identified, addressed, corrected, and resolved…see something, say something.
  • Ensure the Process Technical Specifications (PTS) or Minimum Mandatory Sampling Plan is properly executed and aligned with regional/global requirements.
  • Foster a continuous improvement mindset with the plant quality teams. Support open dialogue to address opportunities in operational efficiencies, quality enhancements or cost reduction initiatives.
  • Lead quality change management: review all new products, process changes and specification changes for the plant Ensure the IPS quality standards are being met prior to approving and changes.
  • Ensure IPS Quality Pillar Food Safety standards are implemented and maintained across the plant operations.

Technical quality Role

• Drive the standardization and execution of quality methods/processes to ensure consistent and repeatable results (data) while maintaining TRUST in the results used for decision making.
• Act as the gate keeper for non-conforming product disposition. Prevent the release of non-conforming product to customers through the effective management of deviations and controls. Provide quality input to the disposition process for non-conforming products or materials as well as slow moving and obsolete (BRaD) raw materials and finished goods, minimizing stock write-off / write down.

Communication & Data Reporting

• Report the quality KPI’s for the plant adhering to the Global KPI calculation policies. Ensure all relevant data is included in the roll up of plant quality results.
• Immediately report major quality and/or food safety failures to your line manager and utilize the regional/global quality resources to more quickly and effectively manage issues.
• Lead the plant quality and operations teams to fully utilize the quality modules in Intelex/Cority/ Q-Pulse to ensure required documentation is collected and maintained for all Ingredion, certification body, customer, or legal requirements.
• Collaborate with regional/global supplier quality to manage raw material compliance and ensure supplier conformance through the TraceGains system.

Internal & External Audits

• Serve as the primary contact for external audits and lead customer, regulatory and certification audits for the plant. Respond in a timely and professional manner to audit non-conformances and any customer and/or regulatory agency inquiries. Coordinate with sales/commercial teams as needed.

Handling queries

• Drive reduction in customer complaints, effectively addressing root causes / systemic issues and improved response times.
• Interface with other functional teams to collaborate on problem products and resolve manufacturing quality challenges.

Qualified candidates will have / be:

Mandatory Requirements

• Master’s degree or higher prefer a degree in Quality, Engineering, Food Science or Food Technology discipline.
• Minimum five (5) years in a management role with relevant experience is required with experience in Quality QA/QC supervisory role, Continuous Improvement (CI), Quality Analytics, or Supplier Management (SQA) roles a plus.
• Fluent in English. In regions where multiple languages are spoken, proficiency in other languages is a plus.
• Experience in leading strategies and implementing standards to drive improvement.
• Customer focused – balance customer and regulatory needs with business goals. Seen as a credible technical leader in customer and/or external interactions.
• Data driven – able to utilize data to make decisions to improve quality / customer lead times, optimize inventory and minimize complexity / reduce costs.
• Knowledgeable in GMP’s, inspection/auditing guidelines, sanitation, food regulations, pest control, and product safety.
   

Desirable Requirements:

• Proficiency in IPS / ISO 9001/ ISO 17025 / HACCP / GFSI Schemes (FSSC 22000/BRC/IFS/SQF) / Halal / Kosher / Organic / Six Sigma or Lean Manufacturing
• Proficiency with Microsoft Office Applications

Required Behaviors & Skills:

• Excellent verbal and written communication skills with proven ability to work cross-functionally within operations (manufacturing & supply chain)
• Ability to lead by example and able to balance Ingredion quality standards with cost impacts to the plant and not jeopardize the company reputation.
• Ability to lead through influence and align multiple stakeholders behind compelling plans – reduces complex issues to simple principles to gain alignment and understanding.
• Strong problem-solving skills using advanced statistical techniques.
• Well-organized, detail orientated and strong leadership abilities with a strong will to succeed.

Relocation Available: