Engineer / Sr. Engineer

Educational Qualification / Experience required :

-Degree in Engineering
- 4 to 7 years of experience in production / assembly line work - Must have experience in handling Blue collar associates

Key Responsibilities :

1. Responsible to achieve production targets as per plan
2. Ensure smooth operations of the production process and shift 3. Ensure adherence to production SOP's, quality and safety standards 4. Participate and contribute to improvement activities to meet targets in cost, quality and delivery involving cross functional interactions / teams 5. Supervise blue collar associates in the production line

Task Analysis:

Indicative Tasks

1. Responsible to achieve production targets as per plan

Prepare the shift plan based on production plan

Review log book, quality documents, communication note to be aware of any issues from previous shift that may impact the current line / shift production

Check for any shortage in materials, manpower and other resources required for production

Allocate work based on the current plan and deploy manpower resources as necessary

Prepare current shift output along with any alternate plan of action for the day to meet contingencies where necessary with the approval of the supervisor (for example, maintenance issues, backlog from previous shifts, ME issues - cutting tools breakages, etc.)

Coordinate with the Stars - Materials, Quality, Production, for availability of materials, quality inspections and to address production issues respectively

Plan timelines and action to achieve the production targets for the shift, i.e. achievement of Adherence to Leveled Production (ALP)

2. Ensure smooth operations of the production process and shift

Check and monitor pre-machining activities, machine setting activities, setting changes and production processes

Conduct visual / random checks on materials, kittings and equipment to detect any malfunctions including areas with issues recorded in previous shifts

Conduct inspection and checks for first piece output in critical areas and machines

Inspect each stage in the production line periodically during shifts to ensure there are no bottlenecks in achieving production targets

Identify and resolve issues that come up during the course of the shift and report those to supervisor which require escalation including machine breakdown, carry forward from previous shifts, other live issues

Conduct first level audits / checks of product quality before handing it over to FG (for example, check for burrs, missing components)

Prepare log book and ensure completion of documentation related to shift

Identify resolution (CAPA) for day to day issues in production line, as appropriate

Track and conduct checks in areas including, new setting changes, new operator assigned to machine, etc.

Plan and coordinate with other functions, as required (for example, change in settings with ME)

3. Ensure adherence to production SOP's, quality and safety standards

Audit definedCritical to Quality (CTQ) are in control

Ensure systems are in place to deliver First Time Right (FTR) production standards

Ensure adherence to SOPs and MSOPs for maintaining continuous workflow

Ensure adherence to defined production process and standards (for example, Single Minute Exchange of Dies (SMED), etc)

Update all documents as required and defined (for example production reports, charts, etc)

Ensure meticulously that all safety standards and instructions are followed

4. Participate and contribute to improvement activities to meet targets in cost, quality and delivery involving cross functional interactions / teams

Prepare and contribute to resolve issues, process improvements in Daily Work Management (DWM), Sunset meetings

Strive to achieve targets of Overall Equipment Efficiency (OEE)

• Ensure controls to achieve cost targets relevant to the production line
• Identify areas for implementing improvement initiatives and eliminating Non Value Adding (NVA) activities
• Conduct 5Y analysis to resolve issues arising in equipment efficiency
• Conduct continuous checks, follow up and adhere to procedures for reducing rejections, rework and customer complaints
• Involve and contribute to analysis of issues related to in process rejections and rework (FIR /RCA/CAPA/Resolution)
• Conduct shop floor audits for 5S, QMS audits and implementation of Panchatantra norms
• Follow up on SMT Scores, Elgi Improvement Tracker (EIT), Higher the Better (HTB) activities and work towards achieving targeted scores and higher points
• Identify and address pain points and bottlenecks in work processes (through analysis, study and also in coordination with ME in areas that may also include reduction of fatigue, etc.)
• Contribute to improvement studies, analysis as part of Cross Functional Team (CFT)
• Meet with suppliers, subcontracting vendors to explain or resolve issues, as necessary
• Track FG goods, stock and WIP to reduce inventory

5. Supervise blue collar associates in the production line

• Provide inputs and On-the-job training (OJT) to blue collar associates on MSOP's

• Motivate associates to follow production process and achieve set production targets
• Create awareness on safety, quality, cost reduction and continuous improvement (Kaizen) norms
• Resolve conflicts and address grievances arising within the team and across teams
• Ensure achievement of productivity output defined for associates
• Train associates to develop multi-skilling across machining and assembly activities