Sr. Engineer IE - Plant

Synopsis of the Role/JD of the role: 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 Regards, Corporate Recruitment Team