Process Engineer (Specialist in developing manual welded New parts)

Role Overview:

As a Process Engineer in the Process Engineering Department, you will play a pivotal role in New Product Development, enhancing the capacity of existing lines, and the development of fixtures and tooling. Your expertise will be crucial in ensuring the Advanced Product Quality Planning (APQP) process is meticulously followed, guaranteeing that parts are manufactured on time and with first-time right quality. This position reports directly to the Senior Manager - Process Engineering.

Key Responsibilities:

Customer Requirements Understanding and Initial Planning:

• Thoroughly understand customer/drawing requirements and translate them into actionable plans.
• Identify special product and process characteristics, considering design specifications and industry standards.
• Prepare comprehensive preliminary process flow, control plan, Failure Mode and Effects Analysis (FMEA), and work instructions to guide the development process.
• Verify Bill of Materials (BOM) inline with SAP and drawing, ensuring accuracy and alignment with project requirements.
• Prepare technical Feasibility Report (TFR) and collaborate closely with quality, production, and engineering teams to address any feasibility challenges.

Process and Equipment Development:

• Identify and assess the need for new equipment, tooling, Inspection, Measurement, and Test Equipment (IMTE), and other facilities required for part development.
• Develop detailed process drawings, including CNC cutting, machining, fabrication, and assembly drawings, ensuring precision and manufacturability.
• Collaborate with design engineers to develop new fixtures tailored to project requirements.
• Conduct rigorous fixture validation trials at supplier end to validate fixture performance and reliability.
• Interact with Industrial Engineering (IE) for layout preparation, optimizing production floor layouts for efficiency and safety.
• Lead the commissioning of fixtures and tools in-house and provide comprehensive training to operators to ensure smooth integration into production processes.

Prototype Development and PPAP Preparation:

• Lead the preparation of parts for the proto sample build and PPAP sample build, ensuring adherence to project timelines and quality standards.
• Act as the primary point of contact for customers, addressing any queries or concerns related to the new product.

Production Support and Capacity Declaration:

• Conduct thorough time studies to accurately assess production capacity and optimize production schedules.
• Manage customers during PPAP audits, ensuring compliance with customer requirements and regulatory standards.
• Oversee significant production runs, monitoring production processes for efficiency and quality.
• Facilitate the seamless handover of fixtures and tools for regular production, ensuring production readiness and operator proficiency.

Product Ramp-up and Knowledge Transfer:

• Monitor the product ramp-up for three months post-production launch, collaborating with production teams to address any teething issues and ensure smooth production flow.
• Facilitate knowledge transfer from New Product Development (NPD) to regular productions, ensuring continuity and efficiency in production processes.

Optimize Manufacturing Processes:

• Analyze current manufacturing processes to identify inefficiencies and areas for improvement. Implement lean manufacturing principles to reduce waste, increase productivity, and improve quality.

Documentation and Reporting:

• Maintain meticulous documentation of all development activities, including reports, drawings, specifications, and project documentation.
• Provide regular updates and progress reports to stakeholders, ensuring transparency and alignment across cross-functional teams.

Qualifications

• Bachelors degree in Mechanical Engineering, Industrial Engineering, or related field.
• 6+ years of experience in process engineering, preferably in the manufacturing of fabricated steel components for construction equipment or mining industries.
• Proficiency in APQP methodologies and tools, including PPAP, FMEA, and Control Plans is preferred.
• Proficiency in CAD software (e.g., SolidWorks, AutoCAD)
• Excellent leadership, communication, and interpersonal skills, with the ability to effectively collaborate with cross-functional teams and external stakeholders.
• Demonstrated ability to manage multiple projects simultaneously, with a strong focus on quality, cost, and timeline management.

Why Join Us:

• Global Exposure: Work on projects that have a worldwide impact, providing a unique opportunity to gain international experience while based in Ranipet.
• Career Growth: Benefit from a dynamic work environment that encourages professional development.
• Work-Life Balance: Enjoy the advantage of being close to home, allowing for a better balance between personal life and career ambitions.
• Recognition: Be part of a company that recognizes and rewards your contributions, offering a path to personal and professional fulfillment.