Job Description:
1. Develop and Implement QC Systems:
- Design and implement a comprehensive quality control system across all production lines (wood, steel, foam, and sewing).
- Establish quality standards and guidelines for each department, ensuring compliance with industry regulations and customer specifications.
- Develop and maintain QC procedures, manuals, and checklists for inspections at different stages of production.
2. Wood Processing QC (Sawmill, Drying, Machining):
- Oversee quality control in sawmill operations to ensure proper grading and sizing of logs.
- Monitor the drying process to ensure wood reaches optimal moisture levels with minimal defects (warping, cracking).
- Inspect raw wood cutting, planning, tenoning, drilling, and sanding processes to ensure accuracy and adherence to product specifications.
3. Finishing QC (Water-Based Finishing, Dip & Hang, Roller Coating):
- Supervise quality checks during the water-based finishing process (both dip & hang and roller coating) to ensure even coating, color consistency, and proper drying.
- Monitor surface finishes for any defects, such as drips, uneven application, or cracking.
- Work with the production team to resolve finishing defects quickly, minimizing rework and scrap.
4. Steel Processing QC (Cutting, Welding, Powder Coating):
- Ensure all steel components are cut and welded accurately according to specifications.
- Supervise the powder coating process, inspecting for smooth application, durability, and adhesion.
- Implement regular inspections for dimensional accuracy, weld integrity, and coating thickness to meet industry standards.
5. Soft Foaming Line QC (PUR Foaming, Cushion, and Sofa Production):
- Oversee the quality of PUR foam production, ensuring consistency in foam density, structure, and firmness.
- Inspect cushions and sofas for defects such as uneven foaming, incorrect sizing, and surface flaws.
- Implement quality checks at different stages of foam production, from block foaming to cushion shaping and covering.
6. Sewing Department QC:
- Establish quality control standards for the sewing department, ensuring proper stitching, seam strength, and material handling.
- Inspect upholstery and fabric components for dimensional accuracy, alignment, and aesthetic quality.
- Work closely with the sewing team to resolve any defects in fabric covers, ensuring high-quality finishes for cushions and sofas.
7. Supplier Quality Management:
- Collaborate with the purchasing department to ensure raw materials (wood, steel, foam, fabrics) meet quality specifications upon receipt.
- Conduct regular audits and evaluations of suppliers to ensure consistent quality in the materials supplied.
- Handle incoming inspections, ensuring raw materials and components meet factory standards before production.
8. Production Process Audits:
- Conduct regular internal audits of production processes across departments to ensure adherence to QC standards.
- Implement spot checks and in-process inspections to identify and address defects before the final product stage.
- Monitor product yield and production efficiency, using data-driven analysis to reduce defects, waste, and rework.
9. Team Leadership and Development:
- Lead and manage the QC team, providing training on inspection techniques, defect identification, and problem-solving.
- Ensure the team understands and implements best practices in quality management across all departments.
- Promote a quality-first culture in the factory, encouraging open communication and collaboration between QC staff and production teams.
10. Data Analysis & Reporting:
- Analyze QC data to identify trends, root causes of defects, and areas for improvement in production processes.
- Prepare regular quality reports for senior management, highlighting performance, areas of concern, and recommendations for improvement.
- Track key performance indicators (KPIs) such as defect rates, rework costs, and customer complaints.
11. Compliance and Safety:
- Ensure all QC activities comply with local regulatory requirements and industry standards (such as ISO 9001, FSC for wood, or specific safety regulations for steel and foam processing).
- Collaborate with the EHS team to ensure safety measures are incorporated into QC practices, especially in high-risk areas like chemical handling (foam production) and powder coating.
12. Customer Complaints & Product Recalls:
- Investigate customer complaints and conduct root cause analysis to identify quality issues.
- Implement corrective and preventive actions (CAPA) to resolve any quality issues, preventing recurrence.
- Manage the process for product recalls if necessary, ensuring proper communication and coordination with production and legal teams.
Requirement:
1. Experience
- Minimum 7-10 years of experience in quality control or assurance, with at least 5 years in a management role, preferably in the furniture manufacturing industry.
- Strong understanding of wood processing, steel fabrication, soft foam production, and sewing processes.
- Experience with water-based finishing, powder coating, and foam chemistry will be highly beneficial.
- English: Good
2. Technical Skills:
- Expertise in using measurement tools and techniques for inspecting wood, steel, foam, and fabric components.
- Proficient in ISO 9001 quality management system (QMS) implementation and auditing.
- Strong knowledge of Lean Manufacturing and Six Sigma methodologies to drive process improvements and reduce defects.
3. Leadership and Communication:
- Proven leadership skills with the ability to manage a diverse QC team and coordinate with other departments.
- Excellent communication skills, both verbal and written, to report findings, propose solutions, and collaborate with production and management teams.
- Ability to handle customer feedback and product complaints professionally, identifying the root causes of issues.
4. Problem-Solving & Analytical Skills:
- Strong analytical skills to review quality data and identify trends, root causes, and areas for improvement.
- Capable of developing effective corrective actions and driving process improvements based on data insights.
5. Education:
- A degree in Industrial Engineering, Manufacturing, Wood Technology, Mechanical Engineering, or a related field.
- Additional certifications in quality management systems (e.g., ISO 9001, Six Sigma Black Belt) are preferred.
6. Attention to Detail:
- Strong attention to detail to identify defects and ensure products meet exacting standards.
- Commitment to maintaining high-quality standards while ensuring production efficiency
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