quality

:Diploma / B.E. / B.Tech in Electrical Engineering, Electrical & Electronics Engineering

About the Role

 We are looking for an experienced Electrical Quality Engineer / Quality Lead to take responsibility for electrical quality across the complete electrical panel assembly and testing process. Our company manufactures and supplies various HT/MV and LT electrical panels and assemblies. Electrical components and switchgear are procured from approved suppliers, while our manufacturing process includes wire processing, harnessing, labeling, electrical component installation, busbar/connection work, control wiring, assembly, testing and Factory Acceptance Testing (FAT). The candidate will be responsible for ensuring that completed panels are electrically correct, fully functional and compliant with approved drawings, specifications, applicable standards and customer requirements.  

Key Responsibilities 

1. Incoming Electrical Component Quality 

Inspect and verify purchased electrical components against: Approved BOM, Purchase specifications, Approved makes, Model numbers, Ratings, Technical specifications, and Approved drawings. Components may include: Circuit breakers, Switchgear, Contactors, Relays, Protection devices CTs/VTs where applicable, Meters, Terminal blocks, Control components, Cables, Wires, Lugs, Ferrules, Cable glands, Connectors, Insulators, Busbar materials, Other electrical accessories.

Verify quantity, identification, physical condition and required certificates/documents.  2. Electrical Drawing & BOM Verification  Ensure assembly is carried out strictly according to:      Single Line Diagrams, Wiring diagrams, Control schematics, GA/component,  layout drawings, BOM, Terminal plans, Interconnection drawings, and      Customer approved drawings

Verify correct component, rating, location and connection.

3. Wire Harness & Control Wiring Quality

Control the complete wire processing process which may include: Wire cutting, Stripping,Ferrule printing, Ferruling, Lug, selection, Crimping,Sleeving, Wire identification, Harness preparation,Routing, Termination, Labelling etc.

Verify:  Wire size, Wire colour, Ferrule number, Terminal number, Component terminal, Correct lug/ferrule, Crimp quality, Strip length, Wire dressing, Routing and segregation, name. etc.

Implement appropriate:

  Pull testing

 Continuity testing

 Point to point verification

 Visual inspection

4. Electrical Assembly Quality

Inspect electrical assembly that may include: Electrical components, Switchgear, Contactors, Relays, Protection devices, Meters, Terminal blocks, Busbars, Insulators, Cable ducts, Control wiring, Power wiring, Cable glands, Terminations, Earthing, Labels, Nameplates

Verify proper mounting, identification and connections.

5. Busbar & Power Connection Quality

Inspect: Busbar material, Busbar size, Configuration, Phase identification, Insulation, Supports, Clearances, Joints, Hardware, Cable lugs, Crimping, Connection, torque etc.

Implement controlled torque procedures using calibrated torque wrenches.

Ensure appropriate torque marking/witness marking and records for critical connections.

6. Electrical Testing

Plan, supervise and/or perform testing of completed panels according to panel type and project requirements. Testing may include:

  Continuity testing

  Insulation Resistance testing

  High Voltage / Dielectric Withstand testing

Earth continuity

  Functional testing

  Control circuit testing

  Trip/close circuit verification

  Protection circuit verification

  Interlock verification

Operational testing

  Timing tests where applicable

Metering verification

Indication testing

  Alarm/annunciation testing

  Control logic testing

  Communication/interface testing where applicable

Ensure test procedures and acceptance criteria are based on applicable standards, approved drawings, equipment ratings, manufacturer requirements and customer specifications.

7. Pre FAT Inspection

Conduct a complete internal inspection before customer FAT.

Verify:

  Mechanical completion

 Electrical completion

  Wiring

 Terminations

 Labels

 Component identification   Testing completion   Functional operation  Documentation

Ensure all internal NCRs and punch points are closed before customer inspection.

8. Factory Acceptance Testing — FAT

Lead or coordinate electrical FAT with:   Customers   Consultants Third party inspectors

Responsibilities include:  Preparing FAT checklists   Demonstrating panel functionality   Demonstrating control/protection functions  Performing required tests   Recording results  Handling customer observations   Closing FAT punch points   Preparing test certificates and reports

The objective is to achieve a high first pass FAT rate and minimize avoidable customer observations.

9. Electrical NCR & CAPA

Handle electrical quality problems including:  Wiring errors   Wrong components   Wrong ratings   Wrong ferrules Wrong terminations   Loose connections  Crimping defects   Testing failures   Functional failures   Drawing related errors   Customer FAT observations

Conduct:  

 5 Why   8D  Root Cause Analysis   Corrective Action  Preventive Action

Track effectiveness and recurring defects.

10. Quality Documentation

Prepare and maintain:   Incoming Electrical Inspection Reports   Wiring Inspection Checklists   Harness Inspection Records   Torque Records

 Electrical Test Reports   IR Test Reports   HV Test Reports where applicable   Functional Test Reports   FAT Reports   NCR Reports   CAPA Records   Final Inspection Reports  Routine Test Certificates   Quality dossiers/documents required for dispatch

11. Testing Equipment & Calibration

Maintain proper calibration and control of:   Megger / IR testers   HV test equipment   Multimeters

 Continuity testers   Electrical test equipment   Torque wrenches  Crimp testing equipment   Other electrical measuring instruments 

Ensure all critical testing equipment is calibrated and within validity.    

12. Process Improvement  Identify and reduce:   Wiring errors   Wrong components   Wrong component ratings   Ferrule errors Crimping defects  Loose connections  Torque related failures  Testing failures  Functional failures   Rework   Customer FAT observations  Customer NCRs   Repeat electrical defects    Required Technical Skills Candidate should have strong practical knowledge of:   HT/MV and LT electrical panels  Electrical panel assembly  Control wiring  Wire harnessing  Ferruling  Crimping  Cable termination  Busbars  Electrical components  Protection/control circuits  Electrical testing  Electrical schematics  SLDs  Wiring diagrams  BOMs  Terminal plans  FAT  NCR/CAPA  Root Cause Analysis  Standards & Compliance Working knowledge of applicable IS, IEC and customer/project standards relating to electrical panels, assemblies, testing and safety. Knowledge of applicable standards such as:  IEC 61439  IEC 62271 series, where applicable to the equipment supplied  Relevant Indian Standards  Customer/project specific specifications The candidate should be able to determine the appropriate testing and acceptance criteria based on the specific equipment, ratings, design and project requirements.    Preferred Experience Experience in HT/MV and LT electrical panel manufacturing, panel assembly, control panel wiring, electrical testing and FAT will be preferred. Candidates who have worked in panel manufacturing companies as Electrical Quality Engineer, Electrical QC Engineer, Testing Engineer, FAT Engineer or Electrical Quality Lead would be suitable.   Key Performance Indicators  Electrical First Pass Yield, Customer FAT First Pass Rate, Wiring defect rate, Crimping/termination defect rate, Testing failure rate, Internal electrical NCR rate, Customer electrical NCR rate, Rework percentage, Repeat defect rate, FAT observation rate, CAPA closure performance, Customer complaint recurrence.   Key Competencies   Strong practical electrical knowledge  Excellent drawing reading ability  Strong troubleshooting skills  Hands on testing experience  Attention to detail  Root Cause Analysis  Quality documentation  Customer/consultant handling  Ability to train electrical assembly technicians  Strong communication skills  Ability to work closely with Engineering, Purchase, Stores, Fabrication, Assembly and Testing teams Primary Objective To ensure that every completed electrical panel is correctly wired, correctly assembled, electrically safe, fully functional, properly tested and compliant with approved drawings, applicable standards and customer requirements before FAT and dispatch.