Body Shop / Assembly Shop Coordinator (Onrole)

Position Name: IE Expert Body Shop Coordinator

Department: Production Systems and Industrial Engineering

Qualification: BE / B Tech / Diploma

Years of Experience: BE: 5+ Years / Diploma 10+ Years

Location : Pune ( Chakan )

Purpose of the Position (Short Summary of the Role):

Industrial engineering (IE) involves applying methods and knowledge for the integrated analysis, evaluation and design of complex systems, structures and processes in the company organisation.

The aim of IE is to optimise both product design and process design, taking into account the social, economic and environmental framework.

Applied IE improves efficiency in the company and ensures humane working conditions.

Purpose of the Position (Short Summary of the Role):

Plan Resources, Workplace design and Process definition in New Projects Production and Logistics (SuMa Specific)

• To define Personnel requirement based on standard process
• Drive HPC Targets in 3P Forum
• Stakeholders Management e.g. Planning, Production and Strategic Productivity Management to align Top down and Bottom up Manpower requirement.
• Inputs for Product optimization (DFMA)
• Business Case evaluations: Personnel requirement planning for specifying the net personnel requirements. Basis: Current process plan, current order programme, current operational circumstances, comparison with productivity targets

Steering & Executing YoY Productivity targets with Stakeholders

• Line balancing Proposal preparation & evaluations
• Cycle time Optimization by Process analysis, Optimization & Standardization through KVP Support
• Increase Value add: Process analysis by Classification Coding tool (Value add, Hidden & Obvious Waste)

Performance Management: Time & Ergonomics

• Implementation of MTM UAS Basic Principles and Procedures
• Management and Controlling of Time management Data
• Development and updating of time and Process building blocks.
• Analysis of Ergonomics by EAWS methodology (Group standard for Ergonomic Workplace analysis
• Risk assessment and mitigation measures through Product, Process optimization for Ergonomics

Project & Special Tasks

• Benchmarking with Brand & group companies
• Testing and Implementation of new IE methods and Systems
• Provide inputs for Brand & Group forums e.g. Planning Round (Strategic & Operational) Peak, Speed+, Digital Shopfloor Journey, Productivity, RPP
• Evaluation of New Projects e.g. BEV, Facelift
• Car Capacity planning: Various JPH Scenarios, Shift Models, Availability, Buffer management for Sub-assemblies, Work Organization measures, Inputs for PPA & Planning rounds.
• Spare part management: MP requirement evaluation on Monthly basis.

Authority:

• Releasing of the People Plan Chart (PPC) on weekly basis.
• Releasing the AP sheets.
• F-Time evaluation in series and pre-series and release for VBZ / ECN / Bridging scenarios / Model Year Changes / Idea Management & PCRN
• Ergonomics evaluation & score calculation for the workstations.
• Deliver PSI KPI strategy topics
• Manpower evaluation & Line balancing steering in case of JPH change or New Projects
• Decision based on benchmarking from other group companies
• Cost and other benefits (FPK, SGK, productivity) calculation in the workshops and projects
• Coaching and management of team of skilled technical staff and direction for setting and establishing standard manufacturing processes with relevant IE competencies.
• Capacity Inputs for Planning rounds (PR.SP & PR.OP)

Skills Required:

Critical Skills :

• Cycle time calculation and line balancing skill
• Knowledge of MTM, EAWS

Technical Skills :

• Knowledge of the manufacturing processes and material handling, equipment in production areas
• Knowledge of AP, Classification Codes.
• Group Systems knowledge: AP/ HWP, MTM, Massnahmen@web
• Workshop moderation and facilitation skills
• Knowledge about process layout, process flow, cost analysis and control, safety needs
• Production Systems methodologies (current series production and new projects)
• Workshop moderation and facilitation skills
• Good problem solving skills
• Proficiency in MS Office packages like Word, Excel, PowerPoint
• Cycle time calculation & line balancing skill

Behavioral skills :

• Effective communication, convincing and assertiveness
• Team Work & Leadership
• Self-Discipline & Self-Motivation; positive attitude
• Interpersonal skills that enable the candidate to effectively interact with operating and executive management and with shop floor Team members
• Presentation Skills

Key Responsibility and Tasks:

Description:

Series and Projects:

• To liaise with internal customers / Stakeholders and internal/external suppliers on projects to ensure that quality, cost and schedule standards are adhered to
• Evaluate existing production processes and propose modifications, improvements or rationalization in order to achieve productivity and/or quality improvements.
• Evaluation of HPC+ manpower Technical services e.g. Measurement, TLD, Rework & QRK
• Attend and participate in various meetings with internal and external customers and eliminate problems.
• Capacity planning: Various JPH & Work Organization Measures Inputs for Planning Rounds

New Model Introduction:

• During the PVS build basic times are to be estimated and timed when possible.
• During the O-series build assist the process engineer and production with training relevant production and quality personnel in order to achieve a competency level that will produce units of an accepted quality level within the set cycle time.
• Assist with the start of production (S.O.P) in order to ensure a smooth transition to the required production volumes.
• Update all applicable systems e.g. Arbeitsplan.

Direct Manpower Management:

• Monitor and report the activities of the Industrial Engineering Department in line with shop agreed targets in order to ensure the effective management of direct manpower and process improvement on the Production lines, Quality and Finish Processes.
• Measure and control the optimization processes within Industrial Engineering to ensure that the monthly and annual productivity targets in line with the agreed plant targets (VBZ /HPC and headcount savings for direct are achieved.
• Ensure the availability of relevant and required systems to perform standard time assessment, operator loading and line balance (Arbeitsplan).
• Ensure that standard times are established for each operation within the production process to ensure that optimum work content and loading targets are achieved for each operator.

Productivity improvements/ Process Improvement opportunities:

• Evaluate equipment and facilities and to advise Maintenance, Planning and Technical Team regarding efficiency improvements.
• Assist in the investigation of process related problems and implementation of solutions/improvements
• Perform capacity studies. Identify Bottlenecks. Resolve constraints to improve JPH (Jobs per Hour) output.
• By analyzing the entire production system to determine where method, production and/or quality improvements are needed.
• Develop more effective production methods by design of layouts, material flow diagrams and SWS sheets for improvements of quality, ergonomics and productivity
• Establish standard times for standard and off standard work by using the appropriate Industrial Engineering tools (i.e. Line Balancing, time study, MTM, related activity-sampling, simulation) and recommend and implement changes where needed.
• Develop or modify systems for measuring plant availability, efficiency and direct run rates.
• Establish together with Process engineers and production SWS sheets, Point plans, line balancing graphs, standard operation sheets etc.
• Facilitate/participate in Process improvement workshops (KVP, Problem solving, focus workshops).

Documentation/Reporting

• Maintain all documentation within VDA 6.1 standards.
• Manage and control the SWS chart database.
• Manage, control, and file the manual time study sheets.
• Manage and control all point plans for the specific production areas.
• Prepare monthly report on activities in area concerned with regard to savings, improved output, ergonomics and manpower levels.
• Manage and control manpower tracking systems in order to advise Production and Human Resources.
• Prepare PPC plan rolled out to departments weekly.

Validation of ideas through Idea management.

Additional Responsibilities :

• To train, mentor and coach IE staff w.r.t.IE competencies.
• To establish IE Systems and ensure smooth implementation.
• Tracking of key performance indicators as per decided frequency and represent the same to PSI management.
• Drive and deliver PSI strategy topics.