Process Engineering Manager

• Develop, implement, and refine manufacturing processes for Laser Cutting, Bending, TIG/MIG Welding, Powder Coating, Painting, Final Assembly, and Utilities.

• Analyze production workflows to identify bottlenecks and inefficiencies, implementing corrective actions.

• Lead Lean Manufacturing, Six Sigma, and Total Productive Maintenance (TPM) initiatives to improve productivity and reduce waste.

• Implement APQP methodologies to ensure structured process design & development and process validation.

• Oversee NPD activities, including feasibility analysis, prototyping, and process validation.

• Conduct Failure Mode and Effects Analysis (FMEA) for design and process risk assessment.

• Ensure compliance with Production Part Approval Process (PPAP) requirements for new product launches.Ensure compliance with Production Part Approval Process (PPAP) requirements for new product launches.

• Collaborate with cross-functional teams (design, quality, procurement) to align product specifications with manufacturing capabilities.

• Oversee the selection, installation, and maintenance of machinery and equipment related to sheet metal fabrication.

• Ensure proper calibration and maintenance of laser cutting machines, bending presses, welding stations, and powder coating and painting systems

• Collaborate with maintenance teams to minimize downtime and optimize machine performance.

Quality Assurance & Compliance:

• Establish and enforce quality control standards for all manufacturing processes.

• Work closely with the Quality Assurance team to ensure adherence to ISO and industry-specific standards.

• Conduct root cause analysis for defects and implement corrective actions.

Performance Metrics & Continuous Improvement:

• Define and track Key Performance Indicators (KPIs) for process efficiency, quality, and cost-effectiveness.

• Monitor Overall Equipment Effectiveness (OEE) to assess machine utilization and productivity.

• Emplement Statistical Process Control (SPC) to ensure process stability and consistency.

• Drive cost reduction initiatives through material optimization and process improvements.

Team Leadership & Training:

• Lead and mentor a team of process engineers, technicians, and operators.

• Develop training programs to enhance technical skills and ensure adherence to best practices.

• Foster a culture of continuous improvement and innovation within the team.

Qualifications & Experience:

• Bachelor’s or Master’s degree in Mechanical Engineering, Industrial Engineering, or a related field.

• 10 ~ 15 years of experience in process engineering within a sheet metal manufacturing environment.

• Strong knowledge of fabrication techniques, welding processes, and surface finishing methods.

• Experience with manufacturing automation is advantageous.

• Familiarity with Lean Manufacturing, Six Sigma, TPM, APQP, and NPD methodologies.

Key Skills:

• Process optimization & troubleshooting

• APQP & NPD implementation

• Leadership & team management

• Quality control & compliance

• Performance metrics & data analysis

• echnical expertise in sheet metal fabrication

• Project management & cross-functional collaboration

• Key Performance Metrics relevant to a Process Engineering Manager in a Sheet Metal Manufacturing organization:

1. Process Efficiency Metrics:-

Overall Equipment Effectiveness (OEE): Measures machine utilization, availability, and performance.

Cycle Time:Time taken to complete a single unit of production.

First Pass Yield (FPY): Percentage of products manufactured correctly without rework.

Scrap Rate:Percentage of material wasted during production.

Rework Rate:Percentage of products requiring corrections before final approval.

2. Quality & Compliance Metrics:-

Defect Rate:Number of defective units per batch or production run.

Process Capability Index (Cp, Cpk):Statistical measure of process stability and consistency.

Customer Complaints & Returns : Number of complaints or returned products due to defects.

ISO Compliance Score:Adherence to industry standards like ISO 9001, ISO 14001.

3. Cost & Resource Utilization Metrics:-

Material Utilization Rate:Percentage of raw material effectively used in production.

Energy Consumption per Unit:Measures efficiency of utilities like DG sets.

Labor Productivity :Output per worker per shift.

Cost per Unit Produced :Total cost incurred per manufactured unit.

4. APQP & NPD Metrics:-

Time-to-Market :Duration from concept to full-scale production.

Prototype Success Rate :Percentage of prototypes meeting design specifications.

PPAP Approval Rate:Percentage of new products passing Production Part Approval Process.

FMEA Effectiveness:Reduction in failure risks due to proactive analysis.

5. Continuous Improvement & Lean Metrics:-

Kaizen Implementation Rate:Number of process improvements executed per quarter.

Six Sigma Defect Reduction:Improvement in defect rates using Six Sigma methodologies.

Lean Waste Reduction : Reduction in non-value-added activities (transport, inventory, motion, etc.).