Asst. Manager/ Dy. Manager

4 weeks ago

pune, India Antal International Full time
Job Description

As a Process Planning and Development Engineer, you will play a crucial role in the development, optimization, and validation of manufacturing processes for PU air filter/elements, air cleaners, hydraulic filters, and associated components. Your responsibilities will include:

A. New Product Development:

Reviewing drawings and specifications for upcoming elements/assemblies to assess manufacturing feasibility. Defining optimal process sequences and identifying potential failure modes, implementing preventive controls and detections. Planning stage-wise quality objectives to ensure right-first-time product development. Conceptualizing and developing necessary jigs, fixtures, and tools for each manufacturing process. Building prototype samples, analyzing gaps, and implementing improvement actions. Conducting process qualification and validation activities, establishing robust process parameters. Developing standard operating procedures (SOP) and work instructions (WI) to standardize processes. Reviewing Bill of Materials (BOM), cycle time, changeover time, and Value Stream Mapping (VSM). Completing Production Part Approval Process (PPAP) and facilitating new product handover activities.

B. Line Process Engineering:

Identifying and leading process improvement initiatives to enhance line productivity, process capabilities, and waste reduction. Utilizing problem-solving methodologies such as 8D, Design of Experiments (DOE), and Statistical Process Control (SPC) to identify root causes and implement corrective actions. Conducting process validation, capability studies, and process audits. Regularly inspecting and validating jigs, fixtures, and tooling used on the production line. Maintaining quality systems and documentation in compliance with IATF standards. Benchmarking manufacturing processes globally and implementing necessary improvements. Driving continuous process improvements to achieve world-class quality and productivity standards.

Key Performance Indicators (KPIs):

Productivity Improvement Cost of Poor Quality (COPQ) / Parts Per Million (PPM) Implementation of Corrective and Preventive Actions (CQC) Process Validation and Capability Improvement On-time delivery of new product development projects (NPD)

Required Knowledge and Skills:

Proficiency in air filter manufacturing processes including welding, filter media processing, adhesive dispensing, and assembly techniques. Understanding of drawing interpretation, manufacturing feasibility studies, process design, and quality planning. Knowledge of process qualification, validation, and capability studies (Cp, CpK, control charts). Familiarity with problem-solving tools such as 8D, Pareto Chart, 5 Whys, DOE, etc. Understanding of tool concept, jig/fixture design, Geometric Dimensioning and Tolerancing (GD&T), and tool cost analysis. Knowledge of production layouts, flow types, takt time, cycle time, and time & motion study. Proficiency in preparing PPAP documents including Process Flow Diagrams (PFD), Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and SOPs. Familiarity with Poka yoke (error-proofing) techniques and automation principles. Understanding of pneumatics, sensors, Human-Machine Interface (HMI), PLCs, etc. is an advantage. Strong analytical and problem-solving skills. Proficiency in AutoCAD or similar 3D modeling tools. Leadership qualities, self-motivation, and teamwork abilities. Willingness to learn and adapt to new areas as per business requirements.

Qualifications:

Bachelor of Engineering (Mechanical) Experience: 5-10 years in a similar role within the manufacturing industry.

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