Manufacturing Engineer

Job Purpose

Responsible for developing, improving and maintaining Final Assembly manufacturing processes to achieve safe, efficient, c ost-effective and high-quality vehicle production.
The role will drive new model introduction, process industrialization, line balancing, cycle-time improvement, ergonomics, automation, quality improvement and continuous improvement across the Final Assembly shop.

Key Responsibilities

Manufacturing Process Engineering
•    Develop and standardize Final Assembly manufacturing processes. 
•    Prepare and maintain Process Flow, Standard Operating Procedures (SOPs), Work Instructions and PFMEA. 
•    Define optimum assembly sequence, workstation layout and process methodology. 
•    Establish cycle time, takt time and manpower requirements. 
•    Conduct line balancing and optimize operator utilization. 

New Model Introduction / Industrialization
•    Lead manufacturing engineering activities for new vehicle / Variants
•    Define process requirements, tooling, fixtures and equipment. 
•    Prepare SOP readiness plans. 
•    Support prototype builds, pilot builds and pre-production trials. 
•    Ensure manufacturing readiness before SOP. 
•    Drive lessons learned from existing models into new builds. 

Line Layout & Capacity Planning
•    Develop Final Assembly line layouts considering: 

o    Material flow 
o    Operator movement 
o    Ergonomics 
o    Safety 
o    Quality 
o    Logistics 
o    Future capacity 

•    Conduct capacity calculations and bottleneck analysis. 
•    Establish cycle-time targets. 
•    Develop & implement line balancing for volume ramp-up. 
•    Identify and eliminate bottleneck operations. 

Tooling, Fixtures & Equipment
•    Define specifications for assembly tools, fixtures and equipment. 
•    Develop requirements for: 

o    Torque tools 
o    Lifting aids 
o    Assembly fixtures 
o    Conveyor systems 
o    AGVs / AMRs 
o    Poka-yoke devices 
o    Testing equipment 
o    Vision systems 
o    Error-proofing systems 

•    Coordinate with suppliers for design, development and commissioning. 
•    Conduct FAT/SAT and equipment acceptance. 
•    Ensure equipment capability meets production requirements. 

Quality & Error Proofing
•    Drive First Time Right / Zero Defect manufacturing. 
•    Develop and implement Poka-yoke solutions. 
•    Conduct process audits.
•    Support analysis of assembly defects using: 

o    4M / 5M 
o    5 Why 
o    Fishbone 
o    DMAIC 

•    Implement corrective and preventive actions. 
•    Ensure critical characteristics and special characteristics are properly controlled. 
•    Improve traceability of critical assembly operations.

Torque & Process Control

•    Define torque requirements and tightening strategies. 
•    Implement controlled tightening systems for critical joints. 
•    Monitor torque-related defects and improve process capability. 

Automation & Industry 4.0
•    Identify opportunities for automation and semi-automation. 
•    Implement digital manufacturing / Industry 4.0 solutions. 
•    Develop: 

o    Andon systems 
o    Digital work instructions 
o    Traceability systems 
o    Torque data integration 
o    Production dashboards 
o    Automated inspection 
o    Vision-based quality checks 

•    Utilize production data for process optimization and predictive improvement. 

Ergonomics & Safety
•    Conduct workstation ergonomic assessments. 
•    Reduce: 

o    Awkward postures 
o    Excessive reaching 
o    Manual lifting 
o    Repetitive movements 
o    Operator walking 

•    Implement ergonomic aids and lifting devices. 
•    Ensure compliance with EHS standards and statutory requirements. 
•    Participate in safety risk assessments and machine/process safety reviews. 

Continuous Improvement
•    Lead Kaizen / CI projects to improve: 
•    Identify and eliminate Muda, Mura and Muri. 
•    Apply Lean Manufacturing, TPM and Six Sigma methodologies. 

Production & Ramp-up Support
•    Provide daily manufacturing engineering support to Production. 
•    Resolve process-related abnormalities and problems. 
•    Support production during volume ramp-up and new model launch. 
•    Lead cross-functional problem solving with Production, Quality, Maintenance, Logistics . 

Key Competencies

•    Final Vehicle Assembly Manufacturing
•    Lean Manufacturing 
•    Line Balancing 
•    Takt Time & Capacity Planning 
•    New Model Introduction 
•    PFMEA & Control Plan 
•    Poka-yoke 
•    Ergonomics 
•    Assembly Tooling & Fixtures 
•    Industry 4.0 
•    Six Sigma / Problem Solving 
•    Project Management 
•    Cross-functional Team Management 

Preferred Experience

Candidates with experience in automotive OEM Final Assembly, particularly in passenger vehicles, commercial vehicles, trucks or buses, with exposure to new model launch, line setup, capacity expansion, automation, process improvement and production ramp-up would be preferred.

Experience
8–12 years in automotive OEM / vehicle assembly manufacturing

Education
B.E./B.Tech in Mechanical / Automobile / Production / Industrial Engineering

Location 

Hoskote