Senior Inspector, QA

Position Summary:

Monitor the production process, inspection and testing of product as per FSPC
Quality procedure (QP-‎01), Work instruction (QW) and Quality Plan (QAP).
Inform shift In-charge verbally or though non-conforming product QF-‎09 for
corrective and preventive action.

Major Responsibilities & Duties performed:

STRAIGTHEING AND CUT LENGTH
* Check the production plan on each straightening machine for inspection.
* Check the straightness and cut length of rebar.
* Check the bundling and tagging of finished product.
* Inform the production operator that, short length pieces should not be added to finished product while in production.
* Record the inspection result in Doc No QF.01A (straightening and cut length inspection report)

CUT AND BEND SECTION
* Check the production plan on each machine for inspection.
* Check the drawing and bar mark.
* Check actual sample and all the dimension should meet as specified in drawing (Production Tag).
* For Epoxy coated fabrication: Check the ends of coated rebar for Touch-up paint.
* Check while bending coated rebar, Teflon mandrels are used to avoid coating damage.
* Check the bundling and tagging condition of finished product.
* Record the inspection result in Doc No QF.01B. (Cut and bend Steel inspection report).

COLD ROLLING LINE
* Check the wire rod coil as per diameter and grade in payoff.
* Take the sample from first spool and check weight per meter.
* Check the sample for dimension: - Diameter, Rib Height, Rib paces, Surface, Tensile Strength, Yield, Elongation.
* Check the finished product spools for proper Tagging.
* Record all the test results of the samples in Doc No QF.01C (Cold Deformed Wire Inspection Report)
WELDED WIRE MESH
* Check the Wire mesh production plan.
* Check the number of Long wire, Cross wire, spacing and overhang w.r.t to Production plan.
* Check the wire mesh sheet size (Dimension).
* Check the wire mesh sheet weight.
* Check the wire mesh sheet for welding quality.
* Check the bundling and tagging on finished product.
* Check Tensile strength of Long Wire and Cross wire.
* Check Weld Shear Force.
* Record the inspection data in Doc No QF.01D (Welded Wire mesh inspection report).

FUSION BONDED EPOXY COATED REBAR LINE.
* Check the black steel rebar suitability for epoxy coating.
* Visual inspection after blasting as SSPC-VIS-SP-‎10.
* Check the blasted rebar for anchor profile, backside contamination, copper sulfate & chloride test.
* Check the required temperature before coating application. (In between ‎232°C TO ‎239°C)
* Once the coating application process is over. Check visually if coating results are satisfactory or not. (If the result are not satisfactory, tell the coating line operator. Coating application needs adjustment (Powder or rebar Temperature).
* Stop the first pass and check the coated rebar for coating thickness (175mircons TO 300microns).
* Check the coated rebar for Coating Continuity test (‎3 holes per meter/ ‎36 holes in 12meter coated rebar is acceptable).
* Check the Coated rebar for coating Flexibility Test (Teflon mandrel ‎6 times the diameter of rebar & ‎180 degree bend is required. Follow Table ‎1 of ASTM A775 for bend test requirements.
* Record the inspection data in Doc No QF.‎11 (Test and Inspection Report of FBEC Rebar)

EPOXY COATED WELDED WIRE MESH
* Check the production plan.
* Check the black Wire Mesh suitability for epoxy coating.
* Check the wire mesh for Bend Sheet, straightness, contamination with oil/grease
* Check the blasted wire mesh surface for anchor profile.
* Check the coated Wire mesh for coating thickness, Coating continuity, Coating flexibility.
* Check the bundling and tagging on finished product.
* Record the inspection data in Doc No QF.11B (Test and Inspection Report of Epoxy Wire mesh).

GALVANIZING LINE
* Check the Galvanized coil diameter with micrometer and diameter mentioned on the Tag.
* Cut around ‎1.5 mtr of Galvanized Wire sample from the finished coil, and noted down the sample details on Sample Tag.
* Test the Galvanized wire sample for Diameter, Zinc Coating and Tensile strength w.r.t customer/product specification.
For Galvanized Armour Wire test the sample for Diameter, Resistivity, Zinc
Coating, Copper Sulphate test, Torsion test and Tensile strength w.r.t
customer/product specification.
* If the Sample meets the specification, put "QC APPROVED" stamp on the Tag.
* If the sample are not as per specification inform the production in charge as well as production operator to take corrective action.
* Recheck the sample and Record the inspection data.
* Check the bundling & tagging on the finished products.
* Record the inspection data in Doc No QF.‎21 (Galvanized Wire Inspection report).

HIGH CARBON PC WIRE.
* Collect the samples from High Carbon M/c,
* Check the Wire Tag for Sample information and record the same.
* Check the wire sample for Diameter and Tensile strength w.r.t product specification.
* If the test result is not meeting the specification, inform production shift in charge as well as production operator to take corrective action.
* Recheck the sample and make sure it meets the specification before starting the Strand production.
* Record the inspection data in Doc No QF.22A (High Carbon Wire Drawing Inspection Report).

Other Responsibilities:

• To understand and follow the organizational policies.


• To follow safety instructions related to their jobs.


• To report damaged PPE, unsafe machines or equipment to concerned staff.


• To keep the provided PPEs in good, workable conditions.


• To avoid any horseplay and abuse of safety devices, equipment and welfare facilities.


• To report any accidents, near misses or hazardous conditions to concerned responsible.


• To attend safety trainings planned for them.


• Having a right to say "NO" to any unsafe work.