Associate Manager - Quality Assurance

A. Woven Fabric Quality Assurance

• Monitor and improve fabric quality at greige, processing, and finished fabric stages.
• Ensure compliance with customer specifications, approved standards, and quality parameters.
• Analyze woven fabric defects such as missing ends, missing picks, broken ends, broken picks, reed marks, weft bars, slubs, stains, holes, selvedge defects, and shade variations where applicable.
• Review fabric inspection reports using the 4-point system or applicable customer inspection standards.
• Monitor fabric rejection, downgrade, rework, and customer complaint trends.

B. Continuous Improvement

• Identify recurring quality issues and implement improvement projects to reduce defects and fabric rejection.
• Apply continuous improvement methodologies such as PDCA, Kaizen, 5 Why Analysis, Fishbone Diagram, Pareto Analysis, and Root Cause Analysis.
• Establish measurable quality improvement targets and monitor progress against KPIs.
• Reduce internal quality costs, rework, wastage, and customer claims.
• Standardize successful improvements through updated SOPs, work instructions, and quality checkpoints.

C. Process Quality Improvement

• Work closely with weaving, warping, sizing, drawing-in, inspection, and finishing teams to eliminate process-related defects.
• Investigate machine-related and process-related quality problems, including loom settings, warp tension, weft insertion, yarn quality, sizing performance, and fabric construction.
• Coordinate with production and maintenance teams to prevent recurring defects and improve process capability.
• Conduct process audits and verify the effectiveness of corrective actions.

D. Quality Data Analysis and Reporting

• Prepare daily, weekly, and monthly quality performance reports.
• Track key performance indicators, including:
  • First-pass yield (FPY)
  • Fabric defect rate and defects per 100 metres
  • Rejection and downgrade percentage
  • Customer complaint rate
  • Rework and wastage percentage
  • CAPA closure and recurrence rates
• Use Excel, dashboards, Pareto charts, and trend analysis to identify improvement opportunities.
• Present improvement results and action plans during quality review meetings.

E. Customer Quality and Compliance

• Investigate customer complaints related to woven fabric quality and coordinate corrective actions.
• Support customer audits, internal audits, and supplier quality assessments.
• Ensure traceability of fabric lots, inspection records, and corrective action documentation.
• Verify that implemented solutions prevent recurrence and meet customer requirements.

F. Training and Team Development

• Train quality inspectors and production personnel on fabric defect identification, inspection methods, and quality standards.
• Promote a quality-at-source culture and encourage employee participation in Kaizen activities.
• Conduct periodic awareness sessions on defect prevention and standard operating procedures.

• Reduction in woven fabric defect rate.
• Reduction in fabric rejection and downgrade percentage.
• Improvement in first-pass yield.
• Reduction in customer complaints and claims.
• Reduction in rework, wastage, and cost of poor quality.
• Timely closure and effectiveness of CAPA.
• Improvement project completion rate and verified cost savings.
• Compliance with inspection standards and process audit requirements.

• Diploma or Bachelor’s degree in Textile Technology, Textile Engineering, or a related discipline.
• Additional training in Quality Management, Six Sigma, Lean Manufacturing, or Continuous Improvement is preferred.

• Strong knowledge of woven fabric construction, weaving processes, and textile defects.
• Expertise in root cause analysis and corrective/preventive action.
• Knowledge of fabric inspection systems, particularly the 4-point system.
• Working knowledge of ISO 9001 quality management principles.
• Proficiency in MS Excel, quality reporting, and data analysis.
• Strong analytical, problem-solving, communication, and coordination skills.
• Ability to lead cross-functional improvement projects and achieve measurable results.

• Consistent improvement in woven fabric quality.
• Lower fabric rejection, rework, and customer complaints.
• Improved process control and defect prevention.
• Better coordination between production and quality teams.
• Sustainable, data-driven continuous improvement across the fabric manufacturing process.