Quality Executive

Role summary

This position is based at the Channo plant in Patiala and focuses on ensuring top-quality output across the PC 32 and 21 lines while strengthening the site’s quality culture. The role covers shift-quality stabilization, control of waste and complaints, product and packaging checks, audit readiness, statutory compliance, complaint resolution, and continuous improvement support.

Key responsibilities

• Oversee quality performance on PC 32 and 21 lines at the Channo plant and help build a strong quality mindset across the site.
• Support the stabilization of quality operations across shifts.
• Track shift KPIs such as WIP, leakages, and zero-red complaints.
• Use strict online inspections and finished-product checks to keep product quality high and customer complaints low.
• Put in place the required quality standards and control systems for processes, plant conditions, and the surrounding work environment.
• Troubleshoot issues during production to reduce waste and protect product quality.
• Maintain GMP, GHK, GLP, and readiness for internal and external audits, including HACCP, AIB, personal hygiene, and process audits.
• Train and develop quality checkers.
• Ensure the potato material issued for production meets quality expectations.

Process-area quality checks

• Carry out online quality inspections in the process area to ensure all PepsiCo standards are followed during shift production.
• Perform visual checks on process conditions and equipment performance.
• Verify that key machine settings remain within the prescribed range for peelers, fryers, slicers, chip conveyors, and seasoning tumblers.
• Check every hour that potatoes in the trim and pare area are peeled properly.
• Review slice thickness and free surface moisture every four hours.
• Decide whether an anti-foaming agent should be added during processing.
• Record dwell time from the operator logbook every four hours.
• Check the level of seasoning applied.
• Run analytical tests to determine whether blanching is needed using the Hunter Color Test.
• Monitor fryer oil usage and ensure it is optimized.
• Test frying oil every four hours for FFA, OV, PV, foreign matter, taste, odor, and specific gravity.
• Compare test outcomes with gold-standard oil usage charts.
• Decide the blend of fresh and used oil for frying.
• Inspect fried chips every hour for TPD parameters such as PA, oil percentage, soft-centered chips, blisters, dark flakes, clusters, and similar defects.
• Measure bulk density, moisture, seasoning, and dimensions for non-PC products.

Corrective action and escalation

• Act on test findings and resolve issues identified during inspections.
• Guide operators on practical corrections for minor issues.
• Tell the shift in-charge how many pickers are needed based on online inspection results.
• Ask the Agro team to change the potato lot if no pickers are available and defect levels are high.
• Share concern areas and corrective measures with the shift in-charge and production manager without delay.
• Escalate critical situations to the Quality Manager, who will then run a complete trial of the lot and make the final decision.

Packaging-area quality checks

• Conduct online inspections and final-product checks in the packaging area to ensure compliance with Frito Lay quality standards.
• Make sure Quality Checkers complete half-hourly air-leakage checks and hourly checks for weight, batch coding, and air fill.
• Perform analytical testing in packaging operations.
• Check oxygen levels in bags every four hours through nitrogen-flushing tests.
• Carry out random film-quality checks whenever special complaints are received from production.
• Share issue areas and corrective steps promptly with operators, the shift in-charge, and the production manager.
• Consult the Quality Manager for critical issues.
• Ensure corrective actions are actually carried out.

Machine monitoring and documentation

• Monitor process and packaging machines closely for quality impact and keep machine-related waste to a minimum.
• Calibrate equipment such as the FL 710e moisture and oil-content detector used after frying.
• Ensure slicer blades are changed every one and a half hours.
• Make sure peeler rollers are replaced regularly to prevent under-peeling or over-peeling.
• Maintain complete and accurate reports for all relevant stakeholders.
• Ensure Quality Checkers prepare end-of-shift air-leakage reports and share them with quality, engineering, and production teams.
• File daily reports and update records consistently.
• Complete the Weak Link Form for oil-test results.
• Prepare a daily quality report for the Quality Manager.
• Keep all quality records updated.
• Ensure operators make quality-related logbook entries every half hour.

Meetings, audits, and inspections

• Run regular quality wall meetings with production and engineering teams to review defects and agree on corrective actions.
• Lead or coordinate a Take Action Wall meeting every four hours.
• Ensure at least four people attend the meeting: the shift in-charge, packaging leader, engineering executive, and quality officer.
• Compare product performance with the gold standard for appearance, taste, and texture, and record scores on a 0–10 scale.
• Decide the right action based on the test score.
• Hold a Mini Wall Meeting one hour after the Take Action Meeting to confirm the action was completed and the issue has been fixed.
• Call a Hot Wall meeting when a critical issue arises.
• Conduct a weekly housekeeping audit to confirm safety and hygiene practices are being followed.
• Inspect process and packaging areas for lighting, shop-floor material placement, and other conditions to ensure they meet standards and remain safe.
• Verify that equipment was cleaned properly the previous Saturday.
• Check visually that all hold material from the previous week has been removed.
• Ensure pest control is carried out on a regular basis.
• Close all non-compliances before start-up.

Hold material, compliance, and complaint handling

• Manage hold material in a way that reduces waste.
• Make sure hold material is cleared within 24 to 48 hours.
• Submit weekly and monthly reports to the Quality Manager covering hold material details and reasons for the hold.
• Assign Red, White, and Yellow Non-Compliance Disposition tags to hold material after a detailed review.
• Report tag status to the production department along with the reason for the hold-up.
• Promote awareness of statutory requirements, including Weights and Measures and FSSAI rules.
• Keep statutory records accurate and up to date.
• Support the Quality Manager in root-cause analysis of customer complaints and in creating a forward action plan.
• Implement the action plan and work to ensure the same complaint does not repeat.

Continuous improvement and control ownership

• Take part in TPM activities and contribute to plant-wide projects.
• Embed quality standards and the idea of cost of quality into day-to-day work.
• Carry out action plans that help institutionalize these practices.
• Share regular feedback with the Quality Manager on the quality culture.
• Support change initiatives and ongoing improvement within the department and the plant.
• Identify improvement opportunities and bring them to the Quality Manager’s attention.
• Execute improvement plans developed by the Quality Manager.
• Ensure compliance with SOX and perform the duties of a Control Owner for the I2C process.
• Document quality procedures, standards, findings, hazards, and corrective actions thoroughly.

Stakeholder interaction and work environment

The role requires frequent interaction with internal stakeholders on daily, weekly, and monthly cycles, including packaging leaders, shift in-charges, and maintenance coordinators for equipment corrections aligned to PepsiCo standards. External coordination may include CFA, 3P, distributors, and sales teams. The position also involves proper training and handholding for quality checks, support from site leadership to deliver results, and handling IR situations related to quality as well as managing contract labour on the shop floor.

Qualifications

• B.Tech in Food Technology, M.Sc. Food Technology, or another relevant discipline.
• Three to five years of exposure to food safety systems and ISO systems.
• Preference for candidates with knowledge of FSSAI, HACCP, AIB, and TPM.