Manufacturing Engineering for new products: (variant)
- 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 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 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
