Sr. Manufacturing Engineer/Industrial Engineer- Plant

1. PRINCIPAL ACCOUNTABILITIES

Manufacturing Engineering for new products: (variant)

• During RFQ stage, study concept drawing and BOM given by R&D and review RFQ for Qty and milestone dates
• Prepare Make or Buy Sheet and prepare Preliminary manufacturing feasibility document for in-house processes.
• Prepare in-house manufacturing planning sheet for investment required along with Process costing input sheet and Capex approval sheet
• Prepare tentative timeline chart for in-house facility development
• Record all the documents in proper files (Soft/Hard) for reference after approvals
• During Proto Phase participate in DFM, DFA and proto sample making and provide inputs related to manufacturability
• Study Development product drawings' as released by R&D and prepare process flow, critical product characteristics list and propose which mfg. cell to use and basic line design and get it reviewed by plant ME Head
• Attend Process Design Review meeting and get approval from BU-ME and Plant Head
• Conduct PFMEA review with CFT members & finalize pokayoke and interlocks required
• Review and modify master list of mass production line facilities and update master development plan, get it approved from plant ME head and release to PM
• Prepare specifications sheets for facilities like Machines, Jigs & fixtures
• Arrange Quotes for machines and Jigs & fixtures via purchase
• Compare quotes and give technical recommendation
• Raise PR and follow-up with purchase for releasing PO
• Interim and final inspection at supplier end to review development status
• Get machine installed and commissioned in plant through maintenance
• Conduct machine trials, prepare tooled up samples, conduct process qualification and process capability studies
• Conduct internal PPAP run with QA as lead
• Submit final Process flow, control plan & PFMEA with IPO

Manufacturing engineering for current products: (variant)

• Prepare and keep cellwise and product wise line capacity sheets updated and get it reviewed by Plant ME Lead Current products for adequacy
• Keep latest shop floor layout ready with due approvals
• Execute debottlenecking projects as given by HOD
• Achieve Quality Improvements by doing defect analysis with QA and take actions on root cause by providing Preventive & Detective countermeasures. Fill PCRN, get it approved and implement
• Do process capability & Process qualification studies as and when required
• Productivity Improvement by Implement low cost automation solution, layout improvements to save manpower
• Update process document like PFC, PFMEA, Control Plan and IPO as and when required

Continuous improvement through Industrial Engineering effort:

• Study production process at granular level and do time study using MOST methodology for new products as well as current products as and when requested
• Analyze opportunities and flow for improvement of workstation ergonomics and implement necessary actions

Jigs, Fixtures, Tools & Gauges Design and documentation: (variant)

• Prepare concept design of Jigs, Fixtures & Process Gauges for New Product Development which is to be approved by Design Lead after design review with requester
• Design & release final tool drawing after approval from manager
• Ensure proper storage & retrieval of latest drawings
• Modify existing tools to achieve improvement in quality, reduction in set-up time &cost as per from process engineer by using pokayoke & SMED concepts
• Arrange new machine, Jigs & Fixtures as per given projects by HOD, follow model specifications for the same; RFQ to supplier, comparison of quotes and preparing technical recommendations etc., fill PR
• Do midterm inspection of new machine, Jigs & Fixture, get them installed by maintenance, do trials and handover to production

2. MAJOR CHALLENGES

• Line availability (to complete all activities in that specific time slot) and no. of try out during new machine installation during NPD phase
• Stringent customer timelines
• Shorter development times for design with many programs coming together

3. DECISIONS

• All Investments and documents review during NPD
• JFG Design Approval
• Decisions on concept design & material selection to be made in consultation with manager
• All decisions to be reviewed with immediate manager before action