Quality Assurance and Control Specialist (QA/QC)


Last Updated: 27th September 2017 (over 5 years ago)

Address
Rawalpindi, Pakistan

E-mail
Locked

Phone Number
Locked

Gender
Male

Age Range
35 to 44

Qualification Level
Degree

Languages
English, Hindi, Punjabi, Urdu

Summary

An energetic, highly motivated and result-oriented professional engineer having strong technical background & extensive knowledge with 14 years of hands-on experience as a “Quality Professional” in oil & gas and manufacturing industries. Highly proficient and proven interpersonal, management, communication, problem solving, decision making and conceptual/analytical thinking skills. Excellent organizational skills with keen attention to detail and a dynamic self-starter with clear ability to assess and prioritize work strategies while promoting the company’s core mission and vision. Have the ability to establish and maintain effective working relationships across all departments with multinational and multicultural team.
Area of Expertise:
• Quality Assurance and Control (QA/QC)
• General Construction QA/QC Supervision
• Supplier Quality Management
• QA/QC Record Management
• Root Cause Failure Investigations/Analysis
• Nondestructive Examination (PT, MT, UT, RT), Welding Inspection, Painting/Coating Inspection, Material Testing and PMI
• Incoming Material Inspection
• Material & Inventory Management and Condition Monitoring
• KPI Development, Monitoring and Analysis
• Team Building and Reward Recognition
• Cross-Functional Collaboration
• Quality Improvement Projects
• Continuous Improvement
• Organizational Process Development
• Managerial Leadership
• Strategic Planning
• Project Management
• Contract Management
• Budget Management
• Risk Assessment, Analysis and Management
• ISO 9001, ISO 14001 & OHSAS 18001, ISO/TS 16949, AS 9100, API Q1, API Q2
• Statistical Process Control Techniques

Education

University of the Punjab, Pakistan
B.Sc. (Engineering)

   Apr 1999
— Jun 2003

Metallurgy and Materials Science

Experience

BP Exploration Limited, (Angola, Africa)
Quality Manager-Wells

   Jul 2013
— Jul 2017

As “Quality Manager-Wells”, I was responsible for providing regional QA/QC support for the design, manufacture, inspection, testing, shop assembly, handling, transportation, storage, preservation and servicing of surface/downhole engineered and rental drilling, completion, intervention & subsea equipment including OCTG in accordance with company requirements and relevant industry standards (API, ISO, ASME, ASTM, AWS, T.H.Hills DS-1, EN etc.).
Identifying, Specifying and Evaluating QA/QC Requirements:
• Identified the QA/QC requirements for contracts/PO/call-off and reviewed/evaluated the suppliers’ QA/QC proposals in RFIs/ RFPs/ RFQs to ensure that it meets company standards, practices and processes.
Review and Approval of QA Documents:
• Reviewed and approved supplier Inspection and Test Plans (ITPs), Quality Inspection Plans (QIPs) and quality control plans (QCPs).
• Reviewed and endorsed inspection/component matrices, exceptions, and deviation/concession requests submitted by the suppliers.
• Provided expert technical feedback on company global equipment integrity and quality assurance/ control practices, guides, procedures or other quality related normative documents.
Supplier QMS Audits, Facility Surveillance Visits and Technical Conformity Assessments:
• Developed checklists and yearly programs/ strategy and conducted several suppliers’ QMS audits, 2nd party technical conformity assessments and, facility surveillance visits.
Quality Control:
• Implemented robust condition monitoring program during storage of wells equipment and assisted PSCM in inventory management.
• Witnessed and monitored assembly’s make-ups, pressure testing, welding inspections, nondestructive examinations (UT, PT, MT, and RT), painting/coating inspection and functional testing as per control points identified in QCPs/ITPs.
Management of TPI/Surveillance Service Providers’ Activities:
• Ensured that TPI contracts are in place and estimated annual budget required for 3rd party surveillance/inspection activities.
• Conducted interviews of inspectors to be used by TPI/surveillance service providers for assurance to meet the company competency requirements.
• Conducted pre-production meetings (PPMs)/pre-inspection meetings (PIMs) and identified surveillance/ inspection activities/ technical documentation reviews.
• Ensured that the surveillance/inspection/testing is planned, arranged and conducted as per company requirements and agreed quality control plans.
• Reviewed inspection reports to ensure the surveillance activities had been performed in accordance with agreed company requirements, issues raised had been closed out, to verify and approve the man hour charge invoices and to verify the company reporting requirements had been followed.
Supplier Quality Management:
• Collaborated with PSCM and discipline engineers for the performance measurement of TPI/surveillance service providers and wells equipment suppliers by collecting/recording performance data and KPI analysis.
Quality Record Management, Staff Training and Continual Improvement:
• Implemented an effective system for tracking, identify and address supplier non-conformances and corrective actions and storage/ retrieval of technical documentation applicable to equipment integrity and quality assurance/control.
• Coordinated with various function within company including discipline engineers, vendors/suppliers, TPIs for the effective use and assurance of resources.
• Conducted RCFAs for field failure of wells equipment and recommended and/or implemented corrective actions.
• Performed a leadership role for local quality specialists. Supervised and trained local assistants and challenger discipline engineers regarding equipment integrity and quality assurance/control requirements, processes and procedures.
• Identified opportunities to deliver continuous improvement in equipment quality, including process efficiency and captured/shared equipment integrity and quality assurance/control lessons learned.

National Engineering and Scientific Commission, Pakistan
Project Director Quality

   Jun 2012
— Jul 2013

As “Project Director Quality ”, I was leader of Quality Management team that comprised of three Quality Managers and four Assistant Quality Managers and twenty inspectors. In addition to leading all quality assurance and control activities of various projects, I managed and monitored my team individuals’ annual performance review and involved in decision making of their promotion, technical performance bonus reward and mentoring in quality discipline. Details of roles and responsibilities were as below;
Quality Management System:
• Ensured that all requirements of quality management system are effectively implemented for maintaining QMS certification.
• Lead internal audits and supplier audits as per annual strategy.
Quality Assurance and Control (QA/QC):
• Implemented comprehensive quality assurance/control processes and procedures, QA/QC plans and inspection test plans (ITPs) according to project requirements and specifications.
• Ensured that all procedures and processes are approved by the organizations and agreed/followed by all interested parties including suppliers/contractors
• Coordinated with concerned departments in planning, organizing and executing the measures necessary for effective quality assurance and control.
• Managed and monitored all inspection related activities with third party inspection agencies including allocation of jobs, day to day follow up regarding work progress, review of non-conformance reported by inspectors, approval of invoices and man-hours applied.
• Reviewed and evaluated subcontractor/supplier and third party inspection service provider performance.
• Collaborated and facilitated the purchase management department to establish QA/QC requirements during pre-qualification phase of new suppliers & subcontractors.
• Managed non-conformity management system and evaluated nonconformities reported during internal audits and by third party inspectors for their acceptance or rejection.
• Ensured that the record of all inspections and testing activities and prepared QA/QC dossier for each project ensuring identification and traceability for easy retrieval.
• Conducted and/or participated in root cause failure analysis in conjunction with discipline engineers and executed the necessary corrective/ preventive actions to resolve issues in a robust and timely fashion.
• Established and tracked QA/QC KPIs based on organization’s overall quality objectives.
• Reviewed, developed & implemented improvements to the existing inspection methods.
Non Destructive Examinations, Welding Inspections and Painting/Coating Inspection:
• Approved nondestructive examination/testing (NDE/NDT) procedures and ensured that all NDT activities are being carried out as per approved and agreed procedures.
• Approved welding inspection reports and welding procedure specifications (WPSs), procedure qualification records (PQRs) and welder performance qualification (WPQs) as per applicable specifications & codes of ASME and API etc.
• Ensured that welding and inspection activities are being performed as per approved procedures.
• Approved the painting/coating, blasting and other paint testing procedures.
• Monitored all painting / coating related works and ensure all final products meet in accordance with company procedures and international codes and standards.
Continual Improvement:
• Identified the continual improvement opportunities, facilitated the development and implementation of continual improvement plan and evaluated the outcomes of the improvements using statistical methods in conjunction with engineering and operations management teams.

National Engineering and Scientific Commission, Pakistan
Quality Manager

   Nov 2009
— Jun 2012

As Quality Manager, I monitored all quality assurance and control activities of various manufacturing projects assigned to me and supervised and mentored four Assistant Quality Managers and several inspectors. I was also responsible to report annual performance rating of my reporting line to project director of quality management. Details of roles and responsibilities were as below;
Implementation of Quality Management System:
• Successfully implemented quality management system (ISO 9001:2008) in organization and acted as “Management Representative (MR)”.
• Facilitated the development of quality policies, quality objectives, processes, procedures, programs and practices in compliance with appropriate standards and regulations for the implementation of quality management system (ISO 9001:2008) in conjunction with various departments.
Quality Management System Auditing:
• Coordinated quality management system audit, reviewed/analyzed audit findings/nonconformities and implemented/suggested appropriate corrective and preventive actions.
• Conducted several quality management system “Internal/1st Party/2nd Party/3rd Party” audits as Auditor/Lead Auditor” for various suppliers and subcontractors of different industry sectors.
Quality Management System Training:
• Conducted several training sessions on quality management systems for internal staff and as a trainer/ lead trainer.
Quality Assurance and Control (QA/QC):
• Contributed in development, organization, communication, promotion and implementation of the total quality management culture, statistical process control, 5S program, kaizen improvement process and six sigma methodologies to control and effectively improve products and service quality.
• Supervised all Inspection and testing activities, reviewed inspection reports, ITPs, QCPs and inspection procedures for fabrication and machining of mechanical structures, pressure vessels, hydraulic systems and pipe manufacturing.
Non Destructive Examinations, Welding Inspections and Painting/Coating Inspection:
• Supervised nondestructive examination/testing (NDE/NDT) activities (VT, PT, MT, UT and RT), reviewed NDT reports and procedures of NDT, Reviewed NDT reports, supervised operation and maintenance of NDE lab facilities and testing equipment.
• Supervised welding inspection activities, reviewed inspection reports and welding procedure specifications (WPSs), procedure qualification records (PQRs) and welder performance qualification (WPQs) as per applicable specifications & codes of ASME and API etc.
• Reviewed painting/coating, blasting and paint testing procedures and supervised all painting / coating work.

National Engineering and Scientific Commission, Pakistan
Assistant Quality Manager

   Jun 2003
— Nov 2009

I started my career in the field of quality management (QA/QC) as Assistant Quality Manager. I learned and developed various skills and competencies required for being a skilled QA/QC specialist. I extensively practiced and conducted all technical and management of QA/QC activities. Details of roles and responsibilities were as below;
Quality Management System:
• Developed and maintained various procedures and records required for implementation of Quality Management System (ISO 9001:2008)
Quality Assurance and Control (QA/QC):
• Verified manufacturing, fabrication and machining of components as per drawing, technical orders and assigned specifications.
• Visual and dimensional inspection of mechanical structures, pressure vessels, hydraulic systems and pipes (as per relevant industry codes and standards of AWS, ASME, ASTM, ISO and API etc.), prepared inspection reports and maintained the inspection records.
• Monitored and assessed the quality of incoming materials through testing and inspection activities to ensure acceptance and compliance with equipment/product specifications.
• Developed and maintained ITPs, QCPs, inspection and testing procedures, report formats etc
Non Destructive Examinations, Welding Inspections and Painting/Coating Inspection:
• Conducted nondestructive examination/testing (NDE/NDT) activities (VT, PT, MT, UT and RT), developed NDT reports and procedures of NDT, operation and maintenance of NDE lab facilities and testing equipment.
• Conducted welding inspection activities, developed inspection reports and welding procedure specifications (WPSs), procedure qualification records (PQRs) and welder performance qualification (WPQs) as per applicable specifications & codes of ASME and API etc.
• Developed painting/coating, blasting and paint testing procedures and monitored all painting / coating works
Destructive Testing/ Material Testing:
• Performed material testing, hardness testing and PMI (positive material identification) of variety of materials according to ASTM and ISO standards. Operated and maintained 100 kN capacity, universal material testing machine (Make: Testometric, UK), XRF, Rockwell, Brinell, Rockwell and Micro hardness testing machines.
Calibration:
• Monitored the calibration and maintained record of mechanical monitoring and measuring equipment including measuring tapes, dial & digital vernier calipers, inside and outside micrometers, depth gauges, dial indicators, tri squares, low & high pressure hydraulic/ pneumatic gauges, torque wrenches etc.

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