Quality Control Engineer

A Quality Inspector (QI) in a small domestic appliances (SDA) assembly plant oversees incoming components, monitors the line, enforces Bureau of Indian Standards (BIS) compliance, and manages testing documentation.

​A structured job description and daily operational framework for this role is outlined below:

​Core Roles & Responsibilities​1. Inward Goods Quality Control (IQC)

• ​Induction & Infrared Cooktops: Inspect Main PCBs and Display/Touch Panels for dry solder, cold solder joints, trace clearances, and component verification (IGBT ratings, bridge rectifiers, capacitors). Check induction coil wire gauge and heat sensor (NTC thermistor) integrity.
• ​Ceiling & Table Fans: Verify motor winding gauge (copper/aluminum specs), capacitor value/tolerance (\mu\text{F}), bearing play/fitment, and blade pitch/weight matching.
• ​Electric Kettles: Inspect heating element resistance, bi-metal thermostat switches (steam switch), auto cut-off triggers, dry-boil protectors, and 3-core cord set ratings.
• ​General Mechanical & Enclosure: Inspect plastic injection-molded housings (flame retardancy check, burrs, sink marks) and ceramic/microcrystalline glass plates for induction units.

​2. In-Process & Assembly Line Quality Control (IPQC)

• ​Conduct line clearance at the start of each shift or model changeover.
• ​Supervise torque settings on pneumatic screwdrivers to prevent plastic cracking or loose ground screws.
• ​Enforce Electrostatic Discharge (ESD) safety protocols at electronic sub-assembly stations.
• ​Identify defect trends during production, log rejection root causes, and work with line supervisors on immediate corrective actions (rework vs. scrap tagging).

​3. Product-Specific Functional & Safety Testing (FQC / OQC)

Appliance

Core Test Parameters

Acceptance Criteria & Target Values

Induction Cooktop

Wattage output, IGBT temperature cut-off, low/high voltage tolerance (160V–270V), pan sensor detection

Correct power draw per wattage stage, auto shut-off if pan is absent within 30–60 seconds.

Electric Fans

RPM measurement, air delivery (sweep angle balance), watt consumption, noise/vibration level

Measured using digital tachometer; smooth bearing operation without wobble or hum.

Electric Kettle

Auto boil cut-off timing, boil-dry safety trip, leakage current

BIS Compliance & Mandatory Electrical Safety Standards

• ​Routine Safety Testing (100% of Units on Line):​High Voltage (HV) / Dielectric Breakdown: Flash testing (typically 1.5\text{ kV} - 1.8\text{ kV} for Class I/II appliances) between live/neutral and accessible metal parts.
• ​Insulation Resistance (IR): Minimum resistance (> 2\text{ M}\Omega or > 5\text{ M}\Omega at 500\text{V DC}) before and after humid condition cycles.
• ​Earth Continuity (Ground Bond): Verifying ground resistance (< 0.1\text{ }\Omega at 10\text{A}-25\text{A} test current) for all earthed appliances (fans, kettles).
• ​Leakage Current: Confirming leakage is within standard limits (\le 0.75\text{ mA} for Class I portable appliances).
• ​BIS Documentation & Scheme of Inspection and Testing (SIT):​Maintain routine and type test logs strictly according to relevant Indian Standards:
• ​IS 302-2-6: Induction cooktops & cooking appliances.
• ​IS 374: Electric ceiling fans (energy efficiency star rating & air delivery).
• ​IS 302-2-15: Electric kettles and liquid heaters.
• ​Ensure batch calibration records are valid for all measuring instruments (wattmeters, digital tachometers, hipot testers, vernier calipers, multimeters).
• ​Prepare documentation for BIS surveillance audits and sample collection logs.

​5. Daily Documentation & Reporting (QA/QC MIS)

• ​Daily Inward Inspection Report (IIR): Supplier part rejection/acceptance rate.
• ​Daily Defect Tracking & First Pass Yield (FPY): Line rejection metrics broken down by component failure vs. operator assembly error.
• ​Daily BIS Safety Test Log: Serialized logs recording HV, IR, and Earth Continuity test values per batch.
• ​CAPA Reports: Corrective and Preventive Action notes issued to suppliers or production supervisors for recurring defects.
• ​Candidate Profile & Skill Requirements​Education: Diploma or B.Tech/B.E. in Electrical & Electronics Engineering (EEE), Electronics & Communication (ECE), or Mechanical Engineering.
• ​Experience: 2–5 years hands-on experience in quality testing on an electrical assembly line (home appliances, consumer durables, or PCBA units).
• ​Technical Skills:​Proficient with digital multimeters, LCR meters, digital tachometers, torque meters, and comprehensive electrical safety testers (HV/IR/Earth bond combos).
• ​Solid understanding of BIS guidelines, SIT schedules, and ISO 9001 quality management systems.
• ​Ability to read component datasheets, circuit schematics, and mechanical assembly drawings.

•  ​Technical Skills:​Proficient with digital multimeters, LCR meters, digital tachometers, torque meters, and comprehensive electrical safety testers (HV/IR/Earth bond combos).
• ​Solid understanding of BIS guidelines, SIT schedules, and ISO 9001 quality management systems.
• ​Ability to read component datasheets, circuit schematics, and mechanical assembly drawings.

•  ​Technical Skills:​Proficient with digital multimeters, LCR meters, digital tachometers, torque meters, and comprehensive electrical safety testers (HV/IR/Earth bond combos).
• ​Solid understanding of BIS guidelines, SIT schedules, and ISO 9001 quality management systems.
• ​Ability to read component datasheets, circuit schematics, and mechanical assembly drawings.