Quality Executive

PepsiCo

Quality Executive

Patiala, Punjab, India

About the job

Overview

•Handling of PC 32 and 21 lines atChanno plant with right qualityproduct & building a quality culture inthe plant.•Stabilization of shift quality

operations.

Ensuring shifts KPls such as WIP/Leakages/ Zero red complaints.• Ensuring best quality of product andminimum customer complaintsthrough stringent on-line qualitycontrol checks and finished productinspection
Implementing right quality controlsystems/standards for the processes,physical systems and environment.•Trouble shooting during online

production to minimize wastage andensure quality.

Responsible for maintaining GMPGHK GLP and internal / external

audits (HACCP AIB, Personal Hygiene,Process audit).

•Train and development of qualitycheckers.

Ensure quality of potato issued forproduction.

Responsibilities

Conducting online quality checks inthe process area to ensure that allPepsico standards of quality arefollowed during the productionprocess in shifts

Conducting visual inspection for;•Ensurina that all kev operatina

parameters of machines are in the

specified range

(Peelers, Fryers, Slicer for thicknessaverage and range, Chip Conveyors,Seasoning Tumblern)
Ensuring after every hour that thepotatoes in the trim and pare area areproperly peeled
Checking slice thickness and freesurface moisture after every 4 hours• Deciding whether to introduceanti-foaming agent in the process•Recording the dwell time from the

operator’s logbook after every 4 hoursChecking the level of seasoningapplied

Conducting analytical tests forDeciding whether blanching isrequired – Hunter Color Test
Ensuring optimum utilization of fryeroil

Conducting 4 hourly checks on oilbeing used for frying for FFA, OV, PV,foreign materials, taste, odor andspecific gravity

Comparing test results against goldstandards oil usage charts

Deciding the mix of fresh and blendedoil to be used for frying operations• Checking the fried chips after everyhour for TPD parameters like PA,percentage oil in the chip, % of softcentered chips, blisters, dark flakes,clusters etc.

Measuring parameters like bulkdensity, moisture, seasoning anddimension for Non-PC products

Taking corrective actions to resolveproblems thrown up by the tests

Providing feedback to operators on

corrective actions that can be takenfor rectifying small problemsCommunicating to the shift in-chargethe number of pickers needed for theprocess area on the basis of onlinechecks

Asking the Agro department tochange the potato lot in case there areno pickers and the number of potatodefects are large

•Communicating concern areas andcorrective actions to the concernedshift in-charge and productionmanager promptly

Informing the Quality Manager in casetest results indicate a crisis situation,who will then conduct a compete trialrun of that lot of potato to take an

appropriate decision

Conductina online auality checks and

finished products’ inspection in thepackaging area to ensure compliancewith Frito Lay standards of quality

Ensuring that the Quality Checkersconduct half hourly checks for airleakage and hourly checks for weight,batch printing and air fill

Conducting analytical tests for• Checking after every four hours thepercentage of oxygen in the bagsNitrogen Flushing tests
Conducting random film qualitychecks on the basis of any specialcomplaints received from the

production department

Communicating concern areas and

Corrective actions to the concerned

operator, shift in-charge andproduction manager promptly

•Consultina the ualitv mananer in

case of criticalities

•Ensuring that the corrective action isimplemented

Monitoring machines in the processand packaging area specifically fortheir effect on quality and ensuringminimum waste due to machinerelated factors

•Calibration of machines like FL 71Oethat detects moisture and % of oil inthe chips after they are fried•Ensuring that the slicer blade is

changed after every 1 and ½ hour• Ensuring that the peeler rollers arechanged periodically to avoid under orover peeling

Maintaining accurate andcomprehensive reports for

communication to all the neonle

Concerned

Ensuring that the quality checkersmake an end of shift report (for airleakage) at the end of every shift andthen circulate it amongst the

concerned people (quality,engineering, production)

•Filing these reports on a daily basis• Filling the Weak Link Fornm to recordthe results of the oil tests

Making a Daily Quality Report for theQuality Manager

•Updation of reports

•Ensuring that the operators makequality relevant entries in their logbooks after every 2 hour•Conducting regular quality wallmeetings with the production andengineering personnel for discussingquality defects detected online andthen deciding the measures to rectify

the problems•Coordinating a “Take Action Wal”meeting after every 4 hours

Ensuring that at least four people viz.shift incharge, packaging leader,engineering executive and the qualityofficer are present for the meeting• Comparing the product with the goldstandard for appearance, flavor,texture and recording the ratings givento the product (ratings will vary

between 0-10)

Deciding on appropriate action for theproduct on the basis of the test

SCoreS

Coordinating a Mini Wall Meeting afteran hour of the Take Action Meeting toensure that the recommended actionhas been carried out and the problemhas been rectified

•Callina for a “Hot Wall” meetina in

case there is a critical problem

Conducting a weekly housekeepingaudit to ensure implementation ofsafety and hygiene practices

Inspecting the process and packagingarea to ensure that the workingconditions like lighting, placement ofmaterial on the shop floor are as perstandard requirenments and that thereare no unsafe conditions in the plant• Ensuring that the equipment havebeen cleaned properly on the previousSaturday
Conducting visual inspection to

ensure that all the hold material of the

previous week is cleared

Ensuring that pest control is doneregularly in the plant
Getting non-compliances rectified

before start-up

Handling the hold material forminimizing wastages

•Ensuring that the hold material iscleared within 24-48 hours of hold-up•Submitting a weekly and monthlyreport to the quality managerregarding the details of the holdmaterial, reasons for the hold-up• Awarding Red, White and YellowNon-Compliance Disposition (NCD)Tags to the hold material after

detailed analysis

•Reporting the status of the tags to theproduction department stating the

reasons for hold-up

Ensuring adherence to statutory lawS(Weights and Measures & FSSAI )

Increasing awareness about statutorylaws

Maintaining accurate statutory

records

Effective resolution of customer

complaints

Assisting the quality manager inanalyzing root causes of conmplaintand developing a forward action planImplementing the action plan• Ensuring the complaint does notOCCur again

Participating in TPM activities forincreased involvement in the

functioning of the plant

•Leading/ participating in TPM forvarious projects undertaken by them.

Practicing a Work Culture ThatPromotes Company Growth

Internalizing quality standards andconcept of ” cost of quality’•Executing the action plans to

institutionalize these

Providing regular feedback to thequality manager on culture
Implementing change initiatives andcontinuous improvement in owndepartment and plant
ldentifying areas of improvement andhighlighting these to Quality Manager
Implementing the action plans

developed by the Quality Manager forcontinuous change

•Ensure compliance with SOX andperform all roles and responsibilitiesas a Control Owner of 12C process• Documenting all quality procedures,systems, standards, findings, hazardsand corrective actions

Quality Executive

Additional Information, Interactions/Complexity

Interact with internal stake holdersdaily, weekly, Monthly basis such aspackaging leader, Shift Incharge,maintenance coordinators for

equipment corrections as Pepsicostandards.

External: CFA, 3P, Distributor, Sales• Proper training and handholding ofOualitv checks

•Having site leadership team support iscritical for the SET to deliver results•Handling the IR situations of Quality(QC), managing Contract Labours@shop floor

Qualifications

•Tech ( Food Tech)/ M.Sc. Food Techor any relevant subjects.

•Exposure to food safety systems andISO systems /3 to 5 years.