Plant QA Manager

Plant QA Manager, RCP

LOCATION: Faisalabad Plant

REPORTS TO: Pakistan Quality Assurance Manager

Company Background:

Ingredion is a global Fortune 500 provider of ingredient solutions that touch millions of lives, every day. With over 19,000 customers in 120 countries, we create solutions that help nourish, comfort, and delight people all over the world. We are proud to source our strength from nature. That's why we're growing sustainably, with an industry-leading product portfolio that includes plant-based proteins, sugar alternatives and clean and simple ingredients that deliver on changing consumer needs while protecting our planet. Although we are best known for our food ingredients, we are much more than a food business. We co-create bespoke solutions with our customers; from cosmetics and beauty to paper and textiles, to pharmaceuticals, driven by relentless curiosity. We make it our business to anticipate industry trends, and to bring together the potential of people, nature, and technology to make life better.

Rafhan Maize is an affiliate of Ingredion Incorporated in Pakistan. Our strategy is a unique blend of volume growth and operational excellence. We are pursuing tri-dimensional strategy to grow organically, geographically and by broadening ingredients portfolio. If you are inspired by professional challenges and the rewards that come from a high level of performance, then Ingredion (Rafhan Maize) is the company for you. At Ingredion (Rafhan Maize) you can be a member of a globally connected team inspired to achieve great things.

We don't just make ingredients. We create possibilities. Be What's Next with us.

The Plant Quality Manager is responsible for leading the plant quality functions and personnel to safely, responsibly, consistently and cost-effectively test and produce products that meet all applicable government, customer and company expectations.

Ensure the plant execution of the IPS Quality Pillar delivers the continuous improvement of results for: in-process rework/downgrades; first pass compliance (FPC) metrics; customer complaints; internal/external audit results.

Core Responsibilities:

Leadership and behavior

• Through the Leadership Competencies of META5, lead all aspects of plant Quality Assurance (QA) and Quality Control (QC).
• Provide leadership and guidance to the quality teams to understand, implement, and sustain the IPS pillars to achieve goals and operate within the annual department budget.
• Ensure IPS Safety Pillar requirements are known and in place for the quality team. Drive quality EHSS management and achieve all EHSS targets and ensure minimum recordable incidents.
• Ensure IPS HR pillar requirements are known and in place for the quality team. Provide leadership in developing, coaching, and supporting the plant Quality team to inspire potential and deliver strong performance. Build Great Talents.

Cultural Improvement

• Improve and develop the plant quality culture. Coordinate Quality Month activities and communication for the plant.
• Ensure plant employees receive training to comply with IPS quality pillar. Verify compliance of internal and external training to meet regulatory and customer requirements.
• Ensure the IPS Reliability Pillar requirements are known and in place for the quality team.
• Ensure the IPS Management Pillar requirements are known and in place for the quality team.
• Manage quality communication to all levels of the plant organization.
• As the plant quality leader and owner of the IPS Quality Pillar:
  • Cascade quality strategy to the site leadership team.
  • Ensure that all work activities of plant employees are performed with attention to the highest standards of quality, food safety, regulatory compliance with all Ingredion, certification body, customer, or legal requirements…doing things right the first time.
  • Track & monitor plant quality performance. Ensure non-conformances/non-compliances are identified, addressed, corrected, and resolved…see something, say something.
  • Ensure the Process Technical Specifications (PTS) or Minimum Mandatory Sampling Plan is properly executed and aligned with regional/global requirements.
  • Foster a continuous improvement mindset with the plant quality teams. Support open dialogue to address opportunities in operational efficiencies, quality enhancements or cost reduction initiatives.
  • Lead quality change management: review all new products, process changes and specification changes for the plant. Ensure the IPS quality standards are being met prior to approving any changes.
  • Ensure IPS Quality Pillar Food Safety standards are implemented and maintained across the plant operations.

Technical quality role

• Drive the standardization and execution of quality methods/processes to ensure consistent and repeatable results (data) while maintaining TRUST in the results used for decision making.
• Act as the gatekeeper for non-conforming product disposition. Prevent the release of non-conforming product to customers through the effective management of deviations and controls. Provide quality input to the disposition process for non-conforming products or materials as well as slow moving and obsolete (BRaD) raw materials and finished goods, minimizing stock write-off / write down.

Communication & Data Reporting

• Report the quality KPI's for the plant adhering to the Global KPI calculation policies. Ensure all relevant data is included in the roll up of plant quality results.
• Immediately report major quality and/or food safety failures to your line manager and utilize the regional/global quality resources to more quickly and effectively manage issues.
• Lead the plant quality and operations teams to fully utilize the quality modules in Intelex/Cority/ Q-Pulse to ensure required documentation is collected and maintained for all Ingredion, certification body, customer, or legal requirements.
• Collaborate with regional/global supplier quality to manage raw material compliance and ensure supplier conformance through the TraceGains system.

Internal & External Audits

• Serve as the primary contact for external audits and lead customer, regulatory and certification audits for the plant. Respond in a timely and professional manner to audit non-conformances and any customer and/or regulatory agency inquiries. Coordinate with sales/commercial teams as needed.

Handling queries

• Drive reduction in customer complaints, effectively addressing root causes/systemic issues and improved response times.
• Interface with other functional teams to collaborate on problem products and resolve manufacturing quality challenges.

Qualified candidates will have / be:

• Master's degree or higher preferably in a Quality, Engineering, Science or Food Technology discipline.
• Minimum 7-10 years of experience with minimum five (5) years in a management role with relevant experience is required, with experience in Quality QA/QC supervisory role, Continuous Improvement (CI), Quality Analytics, or Supplier Management (SQA) roles a plus.
• Fluent in English. In regions where multiple languages are spoken, proficiency in other languages is a plus.
• Well-organized, detail-oriented and strong META5 leadership abilities with a strong will to succeed.
• Excellent verbal and written communication skills required with proven ability to work cross-functionally within operations (manufacturing & supply chain) as well as with innovation and commercial across multiple cultures and locations.
• Experience in leading strategies and implementing standards to drive improvement.
• Ability to lead by example and balance Ingredion quality standards with cost impacts to the plant without jeopardizing the company reputation.
• Ability to lead through influence and align multiple stakeholders behind compelling plans – reducing complex issues to simple principles to gain alignment and understanding. Strong problem-solving skills using advanced statistical techniques.
• Customer-focused – balance customer and regulatory needs with business goals. Seen as a credible technical leader in customer and/or external interactions.
• Data-driven – able to utilize data to make decisions to improve quality/customer lead times, optimize inventory and minimize complexity/reduce costs.

Desired skills

• Proficiency in IPS / ISO 9001/ ISO 17025 / HACCP / GFSI Schemes (FSSC 22000/BRC/IFS/SQF) / Halal / Kosher / Organic / Six Sigma or Lean Manufacturing.
• Knowledgeable in GMP's, inspection/auditing guidelines, sanitation, food regulations, pest control, and product safety.
• Proficiency with Microsoft Office Applications.

Relocation Available: No