Sr. Engineer ME - New Machine Building

• *New Product development Phase: (ME NPD lead Variant)**

• **NPD ME Project Management**
• Ensure for each new program a timeline is prepared by NPD engineer and is in line with customer timeline and follow all APQP steps
• Periodic review of each program and act on delayed activities by communicating to other function stake holders and escalate to PM and plant ME head if remains unresolved and make sure in\-house facility is ready as per plan
• Resource planning as per NPD workload
• Weekly and monthly summary update of own set of product category to plant ME head for his compilation

• **RFQ Phase**
• Review make or Buy sheet, Manufacturing feasibility document, tentative timeline for accuracy of information

• **Proto Phase**
• Review with NPD engineer on their observations from proto sample making event and make sure respective functions R\&D and PM etc. aware of the engineer recommendation

• **Process Design Phase**
• Review process and line design recommendation prepared by NPD engineer and do course correction
• Review PFD, PFMEA and control plan for their accuracy
• Review machine and Jigs\& fixture design requests for adequacy

• **Process Development Phase**
• Support in trouble shooting, if any, by providing technical guidance to NPD engineer
• Resolve inter departmental issues for smooth functionality of NPD engineer

Escalate to plant ME head if issues are unresolved

• *JFG design phase:** **JFG Design lead Variant**

• **Design Work estimation and Delegation**
• Receive design request from M.E. engineers
• Estimate workload and allocate design work to designers per time availability
• Review Progress and make necessary changes

• **Design Approval**
• Check and approve JFG Designs

• **Design Manual**
• Keep on creating design guidelines for critical design points and keep updating design manual

• **Design Quality**
• Promote SMED concepts in design
• Promote pokayoke and interlocks features in JFG Design wherever feasible

• *Current products (In process) phase: (ME Current Product lead Variant)**

• **Capacity Planning**
• Periodically review capacity sheet cellwise and product wise and get it approved from Plant ME head
• Annual capacity planning and proposals for annual budgeting to plant ME Head
• Monthly capacity utilization review and recommend actions to plant ME Head
• Review \& Plan capacity improvement for growth products by de\-bottlenecking, automation etc.

• **Quality Improvements**
• Periodic review of PFMEA, pokayoke and interlock list along with concerned engineer
• Review process defect analysis and its adequacy for preventive/defective controls and get approval from plant ME Head

• **Productivity Improvement**
• Reduce direct manpower by automation, alternate process recommendation, conveyorization for material movement, layout improvement etc.

• **Industrial engineering**
• Lead MOST norm estimation for new products as well as current products as and when requested
• Provide production manpower estimation as per indent plan after analyzing opportunities and flow for improvement of workstation ergonomics and implement necessary actions
• Drive productivity and flow Improvements through industrial engineering effort of line balancing, material flow, man motion, station design study

• **Process Cost Reduction**
• Reduce indirect consumable material wastage by finding alternate low\-cost material like cutting inserts, cutting oil, or with increased life
• Find and propose alternate process with lower process cost

• **Review process Document**
• Review process documents like PFC. Control Plan, PFMEA, IPO updated by following PCRN process
• Keep backup like process qualification reports, process capability reports etc. with approved documents

• **MAJOR CHALLENGES**

(Challenges faced on an on\-going basis in carrying out the job)

• Prioritization of work planned \& budgeted Vs urgent \& unplanned
• Short design Time
• Meeting customer timelines

• **DECISIONS**

(Key decisions which the role needs to escalate to superior)

• All approvals related to investment and document approval
• Design guidelines Approvals

• **DIMENSIONS**

(Key numerical data which will reflect the scope and scale of activities concerning this job)

• **SKILLS AND KNOWLEDGE**

(Minimum acceptable proficiency for this job which best indicates the education and/or experience requirements of this job and not the incumbent)

• *Educational Qualifications**

• Qualifications*

• Minimum Qualification required: BE/B.Tech. – Electrical/Mechanical/Electronics
• Qualifications preferred: MBA – Operations Management.

• Work Experience*

• Minimum 10 to 12 years of experience
• Industry Related experience: Automotive/Auto Ancillary

Other soft skills/competencies

• APQP, LEAN Manufacturing, PFMEA for establishing good process controls,
• Time\-Motion study
• Process knowledge on all critical processes \& correlation between critical parts; Process capability studies
• Analytical and problem\-solving skills
• Auto CAD, Solid Edge Design Skill
• Project Management skills, communication skills, conflict management

Process costing knowledge

• Motor – Process knowledge in winding, Hot stacking, balancing, magnetizing and testing
• FWM – Machining, winding, balancing, magnetizing and testing
• Detail product and process knowledge such as SMT, soldering, dispensing and testing, surface treatment, assembly processes.