Main Purpose –
Vertical startup of green field plant with right quality product & building a quality culture in the plant.
Stabilization of shift quality operations in new green field plant.
Ensuring shifts KPIs such as WIP/ Leakages/ Zero red complain
Ensuring best quality of product and minimum customer complaints through stringent on-line quality control checks and finished product inspection
Implementing right quality control systems/standards for the processes, physical systems and environment.
Trouble shooting during online production to minimize wastage and ensure quality.
Responsible for maintaining GMP, GHK GLP and internal / external audits (HACCP, AIB, Personal Hygiene, Process audit).
Train and development of quality checkers.
Ensure quality of potato issued for production.
Scope– list in priority order the main accountabilities/deliverables of the role, including key measures. These should be clearly the responsibilities of the JOB HOLDER.
Ensuring that the quality of potatoes issued for production is as per the standard specifications
Frying the sample and conducting COOK Test for checking various factors like % of undesirable color, internal defects, greening percentage etc.
Providing status report to the Agro Department and indicating the number of pickers that will be needed for the particular lot (whose responsibility)
Deciding whether the lot should be accepted or rejected
Conducting similar Cook’s Test after every 15 days and whenever required for the potatoes stored in the warehouses under long term storage
Conducting online quality checks in the process area to ensure that all Pepsico standards of quality are followed during the production process in shifts
Conducting visual inspection for;
Ensuring that all key operating parameters of machines are in the specified range
(Peelers, Fryers, Slicer for thickness average and range, Chip Conveyors, Seasoning Tumbler)
Ensuring after every hour that the potatoes in the trim and pare area are properly peeled
Checking slice thickness and free surface moisture after every 4 hours
Deciding whether to introduce anti-foaming agent in the process
Recording the dwell time from the operator’s logbook after every 4 hours
Checking the level of seasoning applied
Conducting analytical tests for
Deciding whether blanching is required – Hunter Color Test
Ensuring optimum utilization of fryer oil
Conducting 4 hourly checks on oil being used for frying for FFA, OV, PV, foreign materials, taste, odor and specific gravity
Comparing test results against gold standards oil usage charts
Deciding the mix of fresh and blended oil to be used for frying operations
Checking the fried chips after every hour for TPD parameters like PA, percentage oil in the chip, % of soft centered chips, blisters, dark flakes, clusters etc.
Measuring parameters like bulk density, moisture, seasoning and dimension for Non-PC products
Taking corrective actions to resolve problems thrown up by the tests
Providing feedback to operators on corrective actions that can be taken for rectifying small problems
Communicating to the shift in-charge the number of pickers needed for the process area on the basis of online checks
Asking the Agro department to change the potato lot in case there are no pickers and the number of potato defects are large
Communicating concern areas and corrective actions to the concerned shift in-charge and production manager promptly
Informing the Quality Manager in case test results indicate a crisis situation, who will then conduct a compete trial run of that lot of potato to take an appropriate decision
Conducting online quality checks and finished products’ inspection in the packaging area to ensure compliance with Frito Lay standards of quality
Ensuring that the Quality Checkers conduct half hourly checks for air leakage and hourly checks for weight, batch printing and air fill
Conducting analytical tests for
Checking after every four hours the percentage of oxygen in the bags – Nitrogen Flushing tests
Conducting random film quality checks on the basis of any special complaints received from the production department
Communicating concern areas and corrective actions to the concerned operator, shift in-charge and production manager promptly
Consulting the quality manager in case of criticalities
Ensuring that the corrective action is implemented
Monitoring machines in the process and packaging area specifically for their effect on quality and ensuring minimum waste due to machine related factors
Calibration of machines like MM55 that detects moisture and % of oil in the chips after they are fried
Ensuring that the slicer blade is changed after every 1 and ½ hour
Ensuring that the peeler rollers are changed periodically to avoid under or over peeling
Maintaining accurate and comprehensive reports for communication to all the people concerned
Ensuring that the quality checkers make an end of shift report (for air leakage) at the end of every shift and then circulate it amongst the concerned people (quality, engineering, production)
Filing these reports on a daily basis
Filling the Weak Link Form to record the results of the oil tests
Making a Daily Quality Report for the Quality Manager
Updation of reports
Ensuring that the operators make quality relevant entries in their log books after every ½ hour
Conducting regular quality wall meetings with the production and engineering personnel for discussing quality defects detected online and then deciding the measures to rectify the problems
Coordinating a “Take Action Wall” meeting after every 4 hours
Ensuring that at least four people viz. shift incharge, packaging leader, engineering executive and the quality officer are present for the meeting
Comparing the product with the gold standard for appearance, flavor, texture and recording the ratings given to the product (ratings will vary between 0-10)
Deciding on appropriate action for the product on the basis of the test scores
Coordinating a Mini Wall Meeting after an hour of the Take Action Meeting to ensure that the recommended action has been carried out and the problem has been rectified
Calling for a “Hot Wall” meeting in case there is a critical probleConducting a weekly housekeeping audit to ensure implementation of safety and hygiene practices Handling the hold material for minimizing wastages
Ensuring adherence to statutory laws (Weights and Measures & PFA
Qualifications/Requirements
B.Tech ( Food Tech)
Exposure to food safety systems and ISO systems / 3 to 5 years.
Preferably Knowledge of FSSAI /HACCP/AIB and TPM.
Relocation Eligible: Eligible for Standard Relocation
Job Type: Regular