Job Title: Manufacturing Engineer
Department:
Manufacturing
Division:
Enviro Division (Air Pollution Control)
Location:
Solapur, Maharashtra
Reports To:
Head – Manufacturing
Job Purpose
To lead and execute the
end-to-end fabrication operations
for
Electrostatic Precipitators (ESPs)
,
Bag Filters
, and
SupportStructures
in the shop. The role ensures
safety, quality, productivity,and cost efficiency
, while maintaining adherence to project timelines,QAPs, and Thermax manufacturing standards.The position carries complete ownership of
shop fabrication activities
,including
material control, contractor management, delivery adherence,inspection coordination
, and
continuous process improvement
.
Key Responsibilities
- Fabrication Execution & Planning
- Plan and execute fabrication of ducts, hoppers, casings, shells, inlet/outlet structures, bag filter housings, and support structures as per drawings and BOM.
- Prepare daily / weekly fabrication schedules aligned to production plans and project delivery requirements.
- Allocate work to fabrication bays, monitor progress, and ensure on-time completion of fabrication, blasting, and painting activities.
- Optimize machine, manpower, and material utilization to achieve productivity and cost targets.
- Material Control & Accounting
- Ensure material receipt, issue, and consumption entries in ERP.
- Maintain accurate traceability and reconciliation of raw materials, plates, consumables, and finished components.
- Track WIP and scrap generation, and implement measures to minimize material wastage.
- Coordinate with Stores, Planning, and SCM for timely availability of input materials.
- Quality Assurance & Inspection
- Ensure adherence to approved drawings, WPS, QAP, and stage inspection plans.
- Conduct in-process checks for fit-up, welding, alignment, dimensional accuracy, surface preparation, and painting quality.
- Coordinate with Thermax QA / TPI / Client Inspectors for inspection clearances and documentation.
- Review and close NCRs, deviations, and ensure implementation of corrective and preventive actions (CAPA).
- Drive zero rework and first-time-right fabrication culture.
- Contractor & Resource Management
- Manage and develop fabrication and welding contractors – assign jobs, monitor progress, verify bills, and evaluate performance.
- Assess contractor manpower, skill levels, and productivity, ensuring adequate resources for planned workloads.
- Implement training, skill certification (welding qualifications), and safety orientation for all contract personnel.
- Negotiate and finalize fabrication rates in consultation with SCM for in-house or outsourced activities.
- Safety, Health & Environment
- Take complete ownership of safety on the shop floor – ensure 100% PPE compliance, safe lifting practices, and risk assessments.
- Conduct toolbox talks, safety audits, and incident investigations regularly.
- Eliminate unsafe acts and conditions through proactive supervision.
- Drive Thermax’s “Safety First” culture and ensure zero accidents in fabrication areas.
- Productivity, Cost & Delivery
- Continuously monitor and improve fabrication cycle times, welding productivity, and material yield.
- Implement Lean Manufacturing, 5S, Kaizen, and visual management systems.
- Analyze daily performance KPIs – tonnage fabricated per day, rework %, OEE, and delivery adherence.
- Support cost-saving initiatives through layout improvement, rework reduction, and process optimization.
- Coordination & Communication
- Liaise with Planning, SCM, Quality, and Projects to align priorities and resolve execution issues.
- Participate in daily production review meetings and provide clear visibility on progress and bottlenecks.
- Coordinate with Design & Engineering for drawing clarifications or feasibility feedback.
- Interface with project teams for inspection, packing, and dispatch readiness.
Skills & Competencies
Technical Skills:
- Strong knowledge of heavy fabrication, welding (SAW, SMAW, MIG), NDT, and painting processes.
- Reading and interpretation of fabrication drawings, welding symbols, and GD&T.
- Familiarity with material standards (IS, ASTM), steel grades, and consumables.
- Understanding of ESP and Bag Filter fabrication sequences, tolerances, and assembly fit-up.
- Proficiency in welding inspection, defect identification, and rectification procedures.
Functional Competencies
- Production planning and control (PPC)
- Vendor and contractor management
- Quality and inspection coordination
- Material management and reconciliation
- Lean manufacturing / continuous improvement
- Cost reduction and productivity improvement
Behavioral Competencies
- Ownership & accountability for outcomes
- Result orientation and sense of urgency
- Strong interpersonal and leadership skills for contractor handling
- Analytical and problem-solving capability
- Teamwork and communication across functions
- Ethical and transparent work practices
IT & ERP Skills
- Proficiency in ERP – PR/PO tracking, material consumption, GRN, and WIP reporting.
- Strong in MS Excel, Word, and PowerPoint for reporting and performance analysis.
- Basic knowledge of AutoCAD / SolidWorks for drawing interpretation.
- Familiarity with digital dashboards, MES systems, and quality tracking tools (preferred).
Educational Qualification
- B.E. / B.Tech / Diploma in Mechanical / Production / Industrial Engineering
Experience
- 5–10 years of experience in fabrication of heavy engineering equipment, preferably in ESPs, Bag Filters, Boilers, or Power Plant Structures.
- Hands-on shop floor experience in fabrication, welding, inspection, and manpower management.
Key Performance Indicators (KPIs)
Parameter
KPI / Target
SafetyZero accident & 100% PPE complianceQualityRework < 2%, NCRs closed within 48 hrsDelivery≥ 95% adherence to fabrication planProductivity≥ Target tons/man-hourMaterial Accounting100% traceability & reconciliationCost Control≤ Approved fabrication cost normsContractor Performance≥ 90% on-time performance5S / KaizenMinimum 2 improvements per quarter
Work Environment
- Full-time presence on Thermax Solapur factory shop floor.
- Coordination with fabrication bays, stores, QA, and planning offices.
- Occasional visits to vendor fabrication units or project sites for quality follow-up or joint inspections.
