Responsibilities
- Oversee facility setup for new projects and process upgrades in brake panel and assembly lines.
- Drive production capacity improvements to align with customer demand forecasts.
- Develop and validate manufacturing processes for new product introductions.
- Work closely with production teams to evaluate and refine current workflows.
- Lead the design, development, and validation of assembly methods to ensure quality and manufacturability.
- Create and implement process documentation such as flow diagrams, assembly instructions, control plans, PFMEA, and packing guidelines.
- Design and refine custom jigs, fixtures, tooling, and assembly aids to improve precision, safety, ergonomics, and throughput.
- Execute continuous improvement projects focused on quality, cycle time, machine uptime, and waste reduction using lean and value engineering principles.
- Collaborate with sourcing to determine make-or-buy strategies for new product components.
- Review technical requirements and confirm manufacturing feasibility during bidding phases.
- Plan workforce allocation and production layout configurations.
- Manage transfer of technology projects from SISCO and secure customer approvals.
- Apply Advanced Product Quality Planning and Failure Mode analysis to meet customer specifications.
- Respond to QRQC issues within the SFU production area.
- Perform data analysis using Minitab, Power BI, or equivalent software tools.
- Demonstrate strong understanding of machinery and test systems, including hardware and software integration.
- Design tools, jigs, and fixtures to streamline production and eliminate inefficiencies.
- Optimize plant layout to reduce lead time and improve operational efficiency.
- Own process design for new products with a focus on Design for Manufacturing principles.
- Maintain comprehensive process documentation, including reports, procedures, and work instructions.
- Supply accurate process timing and routing data to SAP, M3, or ERP systems.
- Launch cost reduction programs targeting yield, productivity, non-value-added elimination, and lead time improvements.
- Identify improvement opportunities and convert them into measurable cost savings.
- Apply lean manufacturing practices such as Kaizen, Six Sigma, JIT, value stream mapping, and capacity modeling.
- Deliver training to technicians and staff on process control methods and tools.
Responsibilities
- Facility creation for new projects and process improvements in SMO brake panel line and AGTU assembly line
- Responsible for Production Capacity Enhancement to meet the customer demand
- Establishment and prove out the process for New Products
- Collaborate with Production team on day-to-day basis to assess & improve the existing processes
- Lead design, development, and validation of assembly processes for production, ensuring manufacturability and quality
- Establishment of process for new products and make corresponding documents like Process flow diagram, Assembly instructions sheet (AIS), PFD, Control plan, PFMEA, Packing Instruction etc.
- Design, develop, and optimize jigs, fixtures, tooling, and assembly aids specific to components to ensure precision, repeatability, throughput, safety, and ergonomics
- Develop continuous improvement activities in quality, cycle times, process improvement, machine availability through lean techniques and value engineering to enhance the capability of existing processes and remove waste
- Knowledge in preparation of Make/Buy with sourcing team for new projects.
- Requirement review and feasibility confirmation during tender phases.
- Manpower and Layout planning.
- Implementation of TOT (Transfer of Technology) projects from our SISCO and gets approval from customers.
- Planning for developing new product using Advanced Product Quality Planning (APQP), Failure Mode & Effects Analysis to ensure product design and performance as per customer requirements
- To respond to the QRQC issues in SFU.
- Data analysis using Minitab, Power BI or similar tools
- Good understanding of the functioning of machines and test systems including both hardware and software knowledge for realizing the product.
- Good understanding and knowledge to design necessary tools, jigs and fixtures to reduce process timings, improve process flow, ease production and to eliminate wasteful activities.
- Layout optimization to improve efficiency and manufacturing lead time
- Responsible for process design for new products/processes and understanding of Design for Manufacturing(DFM)
- Responsible for process documentation- Report writing, data presentation, procedures, work instructions, etc.
- Responsible for providing all necessary process timings and routing information for all products in SAP/ M3/ ERP system
- Initiating cost reduction programs to improve yield, productivity, eliminate NVA, improve lead-time etc. Actively involving in cost reduction activities along with design, quality and production teams.
- Identifying the opportunities for improvements and turning them into cost savings
- Good knowledge and working experience in lean manufacturing practices, Kaizen, Six sigma, JIT initiatives, conducting value stream mapping activities and capacity modeling.
- Providing necessary training to staff and technicians on process control tools and techniques
Other
- Must be able to provide training to staff and technicians on process control tools and techniques
- Must have expertise in creation and finalization of MBOM / PBOM based on process requirement and study from EBOM
- Must be able to conduct time studies, line balancing, throughput optimization, root cause analysis and corrective action implementation
- Must support continuous improvement initiatives (Kaizen, Lean, Six Sigma)
- Must troubleshoot production issues including tooling/jig and assembly process problems
