Industrial Engineer - Winding

Job Title: Industrial Engineer (Winding) - Power Transformers

Department: Manufacturing/Production

Location: Vadodara

Reports To: IE of HOD

Experience: Minimum 4 years of relevant experience in the winding department of a power transformer manufacturing facility.

Knowledge:

• Essential:
• In-depth knowledge of power transformer winding processes, including:
• Disc winding, layer winding, helical winding, and other relevant techniques.
• Conductor handling and processing (copper, aluminum).
• Insulation application and techniques.
• Winding jig and fixture design and utilization.
• Troubleshooting winding-related issues.
• Knowledge of transformer standards (e.g., IEC, IEEE, ANSI).
• Experience with 220 kV class transformers or higher.
• Strong understanding of lean manufacturing principles and continuous improvement methodologies.
• Proficiency in using MS Office Suite (Excel, Word, PowerPoint).
• Desirable:
• Experience with ERP/MRP systems.
• Knowledge of PLC programming and automation.
• Experience with statistical process control (SPC).
• Knowledge of 3D modeling software.
• Experience with root cause analysis techniques (e.g., 5 Why, Fishbone diagram).

Responsibilities:

• Process Optimization:
• Analyze existing winding processes to identify bottlenecks and areas for improvement.
• Develop and implement process improvements to enhance efficiency, reduce costs, and improve quality.
• Conduct time and motion studies to optimize work cycles and improve productivity.
• Implement lean manufacturing principles (e.g., 5S, Kaizen) to streamline operations.
• Quality Control:
• Monitor winding operations to ensure adherence to quality standards and specifications.
• Conduct quality inspections and tests at various stages of the winding process.
• Analyze quality data to identify and address root causes of defects.
• Develop and implement corrective and preventive actions to minimize defects.
• Production Planning & Scheduling:
• Assist in developing and maintaining production schedules for the winding department.
• Monitor production progress and identify potential delays.
• Coordinate with other departments (e.g., core making, assembly) to ensure smooth workflow.
• Equipment Maintenance:
• Oversee the maintenance and calibration of winding equipment.
• Troubleshoot equipment malfunctions and coordinate repairs.
• Participate in the selection and procurement of new winding equipment.
• Safety & Ergonomics:
• Ensure a safe working environment for all winding personnel.
• Conduct safety inspections and implement safety measures.
• Design and implement ergonomic improvements to reduce worker fatigue and injuries.
• Training & Development:
• Train and mentor winding personnel on new processes, techniques, and safety procedures.
• Develop and conduct training programs to enhance the skills of winding personnel.
• Documentation & Reporting:
• Maintain accurate records of winding operations, including production data, quality reports, and maintenance logs.
• Prepare reports on winding performance, process improvements, and quality trends.

Skills:

• Analytical and problem-solving skills: Ability to analyze complex problems, identify root causes, and develop effective solutions.
• Communication and interpersonal skills: Excellent written and verbal communication skills. Ability to effectively communicate with colleagues, supervisors, and other departments.
• Organizational and planning skills: Ability to prioritize tasks, meet deadlines, and manage multiple projects simultaneously.
• Teamwork and collaboration skills: Ability to work effectively in a team environment and collaborate with other departments.
• Continuous improvement mindset: A strong drive for continuous improvement and a willingness to embrace new ideas and technologies.