Synopsis of the Role/JD of the role:

Manufacturing Engineering for new products: 

· 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

Manufacturing Engineering for new products

Lead Manufacturing

Time Study

Capacity calculation

Line Balancing

Motion Study

Continuous Improvement