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Salary12-15 LPALocationPune, IndiaJob Description
As a Process Planning and Development Engineer, you will play a crucial role in the development, optimization, and validation of manufacturing processes for PU air filter/elements, air cleaners, hydraulic filters, and associated components. Your responsibilities will include:
A. New Product Development:
- Reviewing drawings and specifications for upcoming elements/assemblies to assess manufacturing feasibility.
- Defining optimal process sequences and identifying potential failure modes, implementing preventive controls and detections.
- Planning stage-wise quality objectives to ensure right-first-time product development.
- Conceptualizing and developing necessary jigs, fixtures, and tools for each manufacturing process.
- Building prototype samples, analyzing gaps, and implementing improvement actions.
- Conducting process qualification and validation activities, establishing robust process parameters.
- Developing standard operating procedures (SOP) and work instructions (WI) to standardize processes.
- Reviewing Bill of Materials (BOM), cycle time, changeover time, and Value Stream Mapping (VSM).
- Completing Production Part Approval Process (PPAP) and facilitating new product handover activities.
B. Line Process Engineering:
- Identifying and leading process improvement initiatives to enhance line productivity, process capabilities, and waste reduction.
- Utilizing problem-solving methodologies such as 8D, Design of Experiments (DOE), and Statistical Process Control (SPC) to identify root causes and implement corrective actions.
- Conducting process validation, capability studies, and process audits.
- Regularly inspecting and validating jigs, fixtures, and tooling used on the production line.
- Maintaining quality systems and documentation in compliance with IATF standards.
- Benchmarking manufacturing processes globally and implementing necessary improvements.
- Driving continuous process improvements to achieve world-class quality and productivity standards.
Key Performance Indicators (KPIs):
- Productivity Improvement
- Cost of Poor Quality (COPQ) / Parts Per Million (PPM)
- Implementation of Corrective and Preventive Actions (CQC)
- Process Validation and Capability Improvement
- On-time delivery of new product development projects (NPD)
Required Knowledge and Skills:
- Proficiency in air filter manufacturing processes including welding, filter media processing, adhesive dispensing, and assembly techniques.
- Understanding of drawing interpretation, manufacturing feasibility studies, process design, and quality planning.
- Knowledge of process qualification, validation, and capability studies (Cp, CpK, control charts).
- Familiarity with problem-solving tools such as 8D, Pareto Chart, 5 Whys, DOE, etc.
- Understanding of tool concept, jig/fixture design, Geometric Dimensioning and Tolerancing (GD&T), and tool cost analysis.
- Knowledge of production layouts, flow types, takt time, cycle time, and time & motion study.
- Proficiency in preparing PPAP documents including Process Flow Diagrams (PFD), Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and SOPs.
- Familiarity with Poka yoke (error-proofing) techniques and automation principles.
- Understanding of pneumatics, sensors, Human-Machine Interface (HMI), PLCs, etc. is an advantage.
- Strong analytical and problem-solving skills.
- Proficiency in AutoCAD or similar 3D modeling tools.
- Leadership qualities, self-motivation, and teamwork abilities.
- Willingness to learn and adapt to new areas as per business requirements.
Qualifications:
- Bachelor of Engineering (Mechanical)
- Experience: 5-10 years in a similar role within the manufacturing industry.
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