Water world is For Fishers, Man is on Earth

Job Description

Bachelor s or Master s degree in Mechanical Engineering, Industrial Engineering, or a related field. Job Summary: The Process Engineering Manager is responsible for optimizing and improving manufacturing processes to enhance efficiency, quality, and cost-effectiveness. This role involves overseeing key sheet metal fabrication processes, ensuring compliance with industry standards, and driving continuous improvement initiatives. Additionally, the role integrates APQP methodologies and NPD activities to ensure robust product development and process validation. Key Responsibilities: Process Optimization & Improvement: - 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. Advanced Product Quality Planning (APQP) & New Product Development (NPD): - 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. Technical Leadership & Equipment Management: - 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 Process Engineering Manager Sheet Metal Manufacturing 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. 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. 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.). Enter valid string Nutrition, hygiene, adequate food for All Formation and mobilization of an active and vigilant canteen committee for providing hygiene and nutritious food to employees and visitors. INTEGRA renovated a well-equipped kitchen facility for tribal school for Kids. Donation of an automatic Roti maker machine to a rural school (Javaher Ashramshala, Jambughoda) for taking care of school children s food problems. Health creates Wealth Distribution of newborn baby kits for the well-being of infant kids by INTEGRA. On site Health awareness session by Experts at INTEGRA. A fully equipped OHC centre and expert consultation from Doctor. Yearly Blood donation camps by employees of INTEGRA. Yearly Health check of Employees. Renovation of Toilet and washroom facilities for girls students at Javaher Ashram Shala in remote tribal areas of Jambugodha. Construction of Septic Tanks for Hygiene, and cleanses of residential students CSR work done at Shri Manakelal Maganlal Gandhi School & Javahar Ashram Shala in remote tribal areas of Jambugodha. Renovation of Kitchen Renovation of Class Room. Distribution of Sports equipment. Reconstruction of the Roof of School Buildings Conducting on site skill-enhancing ( welders ) training programs for local students. Increasing women employees in the organization at all levels. Proactively arranging career development programmes for women (Minimum 6 per year). Sexual harassment policy and Internal complain committee are designed to protect human rights for women. Hygiene and Health | Hand in Hand Achieving water adequacy for drinking, sanitation by rainwater harvesting for improved level of Ground Water and efficient recycling of wastewater through ETP & STP. Providing Quality drinking water through RO plants and water coolers at various places . Supplementing water bodies to increase groundwater levels with participation from communities. Good network of Rainwater harvesting. Initiating and Implementing Swachh Bharat Abhiyan on INTEGRA s Sites. Getting Closer to Nature Solar is the Future INTEGRA is planning to Increase the use of renewable energy through - Solar rooftops ( 625 KVA, against requirement of 650 KVA ) to make us self reliant for energy. Using Solar streetlights within premises. Using Electric Forklift in place of diesel forklift to minimize CO2 emission. Growing together by Social contribution Employable skill training in underprivileged communities Conducting on site skill-enhancing ( welders ) training programs for local students. Placements for graduate trainees. Employment of, physically challenged persons to attain cultural diversity at INTEGRA. On-site training of Don Bosco High school children in behavior, skill development career planning in underprivileged communities by INTEGRA. INTEGRA is specially awarded by District authority for giving the highest employment in rural areas in year 2022. Dedication to Make in India initiatives to create employment opportunities. INTEGRA did innovation in storage technology by implementing Automatic V store facility. Making industry more sustainable by enhancing infrastructure. Minimizing human efforts by innovative automation through INTEGRA s successful Kaizen Drive . Established policies to empower employees irrespective of gender, age, disability, race, and religion. Encouraging employment of female employees. Bias-free employment and opportunities for especially challenged, and/or minorities. Erasing animosity arising out of discrimination We are careful to take care that our Products and Services add NO Harm to cities and communities. INTEGRA takes due care that there is NO traffic congestion due to its daily operation Conserve Energy and Materials through Less Scrap, Less Waste Efficient utilization of RM sheets with the help of Hitech nesting software gives INTEGRA more than 90% of material utilization. INTEGRA is now using thyristor/IGBT base welding machine in place of the conventional machine to minimize electrical loss and improve power factor. Re-using Non hazardous waste of sheet metal. Changing the climate is nature s job, not ours INTEGRA takes due care of climate by : Using dipping Technology in acid pickling process to control GHG emissions Using acid fume scrubber to mitigate GHG emissions effect More use of electric forklifts in place of diesel forklifts to reduce CO2 emissions 625 KVA of renewable energy ( Solar) planned in FY23-24 for all operational energy demand Regular tree plantation every year in monsoon season. Efficient water treatment of wastewater by ETP and STP Discourage contamination and overexploitation of groundwater Alignment with pollution control board regulations, Government of Gujarat, India Water world is for Fishers, Man is on Earth All waste waters ( Industrial & domestic ) are treated precisely through ETP & STP as per government regulations. INTEGRA takes care of the Biodiversity system of this planet. Fecal coliform test is performed on wastewater to ensure that treated water is not harmful to any living being. INTEGRA has efficient rainwater harvesting in our facility to sustain water bed levels. Planted 550 saplings in FY 22-23 and many fully-grown trees are nurtured at our locations. Optimizing the use of natural resources to sustain natural balance. Follow Justice & Ethics : our basis tactics INTEGRA has strong vigil mechanism to control fraud, bribery , corruption at all level. A full proof grievance mechanism and employment guidelines to avoid work place discrimination and sustain cultural diversity. Sexual harassment policy and Internal complain committee are designed to protect human rights for women. Supporting the Government, Governing for the Goals INTEGRA collaborates with state and national Government officials to comply with all statutory regulatory requirements in time. Tying with local NGOs for impartial treatment to sexual harassment cases. INTEGRA operates hand in hand with local ITI colleges for recruitment as well as giving training to the local students. Maintaining supplier sustainability by sharing best practices of EHS, Ethics with business partners.