JOB DESCRIPTION – QC MANAGER

Job Title: Quality Control Manager (QC Manager)
Department: Quality Control
Reports To: Plant / General Manager
Industry: LSAW Steel Pipe Manufacturing
Location: Dammam 2nd Industrial City, Saudi Arabia

A. Job Purpose

The QC Manager is responsible for managing and controlling all Quality Control activities related to the manufacturing of LSAW steel pipes, ensuring that raw materials, welding processes, production stages, inspection, testing, coating-related inspections where applicable, and finished products comply with applicable international standards, customer specifications, Saudi Aramco requirements, and approved project quality documents.

The position is responsible for leading the QC team, maintaining effective inspection and testing controls throughout the manufacturing process, and ensuring that only compliant products are released to customers.

B. Key Roles & Responsibilities

1. Quality Control Management

• Manage and supervise all QC activities throughout the complete LSAW pipe manufacturing process.
• Develop, review, implement, and maintain Quality Control Plans (QCP), Inspection & Test Plans (ITP), inspection procedures, checklists, and related QC documentation.
• Ensure manufacturing and inspection activities comply with applicable standards, customer specifications, approved procedures, and project requirements.
• Coordinate QC activities with Production, Welding, Engineering, Maintenance, Planning, and other relevant departments.
• Establish inspection priorities based on production schedules and project requirements.
• Ensure proper allocation of QC inspectors and NDT personnel across production and inspection activities.
• Monitor QC performance and provide regular quality reports to management.

2. LSAW Pipe Manufacturing Quality Control

Ensure proper inspection and quality control throughout applicable manufacturing stages, including:

• Incoming raw material and steel plate inspection.
• Material identification and traceability.
• Plate dimensions and visual inspection.
• Edge preparation and milling inspection.
• Forming process inspection.
• Tack welding and continuous welding inspection.
• Internal and external Submerged Arc Welding (SAW) inspection.
• Weld visual and dimensional inspection.
• NDT activities.
• Mechanical and destructive testing.
• Hydrostatic testing.
• Pipe dimensional inspection.
• Straightness, diameter, wall thickness, length, and end preparation inspection.
• Final visual inspection.
• Marking and traceability verification.
• Final release and documentation review.

3. Welding Quality Control

• Ensure welding activities are performed according to approved Welding Procedure Specifications (WPS).
• Verify applicable Procedure Qualification Records (PQR) and welder/welding operator qualifications.
• Monitor welding parameters and compliance with approved manufacturing procedures.
• Coordinate with Welding Engineers, Production, and QC personnel regarding welding quality issues.
• Review welding defects, repair rates, and recurring quality problems.
• Ensure weld repair activities are properly controlled, inspected, documented, and accepted according to applicable requirements.

4. NDT Management

Manage and control NDT activities applicable to LSAW pipe manufacturing, including:

• Ultrasonic Testing (UT).
• Automated Ultrasonic Testing (AUT), where applicable.
• Radiographic Testing / RTFI, where applicable.
• Magnetic Particle Testing (MT/MPI).
• Liquid Penetrant Testing (PT/LPT), where applicable.
• Other required NDT methods according to applicable specifications.
• Ensure NDT personnel hold valid and appropriate qualifications/certifications.
• Ensure NDT procedures are approved and properly implemented.
• Coordinate and supervise NDT Level II personnel and activities under the applicable Level III framework.
• Review NDT reports, indications, rejection rates, and repair results.
• Ensure NDT equipment calibration and verification requirements are maintained.

5. Saudi Aramco & Customer Requirements

• Ensure compliance with applicable Saudi Aramco specifications, standards, project requirements, and approved procedures.
• Coordinate quality-related matters with Saudi Aramco representatives, customer inspectors, Third-Party Inspection Agencies (TPI), and other client representatives.
• Support and manage customer surveillance, inspection hold points, witness points, and final inspections.
• Ensure inspection notifications are issued and coordinated according to project requirements.
• Review customer comments and ensure timely closure of quality-related observations.
• Participate in Saudi Aramco/customer quality meetings and inspections when required.
• Ensure readiness for customer and vendor quality audits.

6. Applicable Standards & Specifications

The QC Manager shall have strong working knowledge of applicable standards and specifications, including but not limited to:

• API Specification 5L
• ISO 9001 – Quality Management Systems
• Applicable Saudi Aramco Engineering Standards (SAES)
• Applicable Saudi Aramco Materials System Specifications (SAMSS)
• Applicable ASTM / ASME standards
• Customer-specific technical and quality requirements
• Applicable welding and NDT standards and codes

7. Non-Conformance & Corrective Actions

• Manage Non-Conformance Reports (NCRs) related to manufacturing and product quality.
• Investigate quality failures and recurring defects.
• Lead or participate in Root Cause Analysis (RCA).
• Establish corrective and preventive actions in coordination with relevant departments.
• Monitor implementation and effectiveness of corrective actions.
• Analyze rejection, repair, and defect trends to identify opportunities for improvement.
• Prevent release or shipment of non-conforming products.

8. Inspection & Testing

Ensure proper execution and documentation of required inspection and testing activities, including:

• Visual inspection.
• Dimensional inspection.
• NDT.
• Hydrostatic testing.
• Tensile testing.
• Bend testing.
• Charpy Impact Testing (CVN), where applicable.
• Hardness testing, where applicable.
• Drop Weight Tear Test (DWTT), where applicable.
• Macro / metallographic examinations, where applicable.
• Chemical composition verification.
• Other mechanical and laboratory tests required by API 5L, Saudi Aramco, or customer specifications.

9. Calibration & Inspection Equipment

• Ensure measuring, inspection, and testing equipment is properly calibrated and controlled.
• Maintain calibration schedules and records.
• Ensure expired or non-conforming measuring equipment is prevented from use.
• Coordinate calibration activities with approved laboratories and service providers where required.

10. Documentation & Traceability

• Ensure complete traceability of materials from incoming steel plate through finished pipe.
• Ensure Heat Numbers, Pipe Numbers, inspection status, test results, and manufacturing records are properly maintained.
• Review and approve QC records and inspection reports.
• Ensure preparation and completeness of Manufacturing Record Books / Manufacturing Data Records (MRB/MDR) as required by customers.
• Ensure quality documents are properly maintained and retrievable for audits and customer review.
• Coordinate final quality documentation prior to product release and shipment.

11. Audits & Quality Improvement

• Participate in internal, external, customer, and certification audits.
• Ensure QC department readiness for Saudi Aramco and other customer audits.
• Follow up audit findings and ensure timely closure.
• Identify opportunities to improve inspection effectiveness and reduce rejection/rework rates.
• Monitor quality KPIs and report significant trends to management.

12. Team Management

• Lead and supervise QC Engineers, Welding Inspectors, General Inspectors, NDT Inspectors/Technicians, Process Controllers, and other QC personnel.
• Evaluate competency and performance of QC personnel.
• Identify training and certification requirements for QC staff.
• Ensure inspectors are assigned according to their qualifications and competency.
• Support recruitment and technical evaluation of QC personnel when required.
• Promote quality awareness and compliance throughout the manufacturing operation.

C. Qualifications & Experience

• Bachelor’s Degree in Mechanical Engineering, Materials Engineering, Metallurgical Engineering, Welding Engineering, or related engineering discipline.
• Minimum 10 years of relevant Quality Control / Quality experience, preferably within steel pipe manufacturing.
• Minimum 5 years in a supervisory or managerial QC position is preferred.
• Strong previous experience in LSAW pipe manufacturing is highly preferred.
• Proven experience with API 5L line pipe manufacturing and inspection.
• Previous experience working with Saudi Aramco projects and requirements is highly preferred.
• Strong knowledge of welding, SAW processes, NDT, mechanical testing, dimensional inspection, and hydrostatic testing.
• Strong knowledge of ISO 9001 Quality Management System requirements.
• Experience dealing with customers, Third-Party Inspectors, and external auditors.
• Strong English communication and technical report-writing skills.

D. Preferred Certifications

The following certifications are highly preferred:

• CSWIP 3.1 / CSWIP 3.2
• AWS-CWI or equivalent welding inspection certification
• ASNT NDT Level II / Level III or equivalent recognized certification
• ISO 9001 Lead Auditor / Internal Auditor
• API-related training or certifications relevant to line pipe manufacturing

E. Key Competencies

• LSAW Pipe Manufacturing Knowledge
• API 5L Requirements
• Saudi Aramco Quality Requirements
• Welding & SAW Process Knowledge
• NDT & Inspection Management
• Quality Control Planning
• Root Cause Analysis
• NCR & Corrective Action Management
• Technical Documentation
• Material Traceability
• Audit Management
• Team Leadership
• Customer & TPI Coordination
• Problem Solving & Decision Making
• Quality Performance Analysis

F. Accountability & Authority

The QC Manager shall have the authority to:

• Stop or hold manufacturing activities when serious quality non-conformities are identified.
• Reject materials, processes, or products that do not comply with approved requirements.
• Prevent release or shipment of non-conforming products.
• Require corrective actions from relevant departments for identified quality issues.
• Approve QC inspection records and product release documentation within the assigned authority.
• Escalate significant quality risks and non-conformities to senior management.
• Ensure all products released by QC comply with applicable specifications, standards, and customer requirements.

The employee shall perform any additional duties related to Quality Control and Quality Management as assigned by the Plant Manager or Management.