Career

Process Engineering Manager

Experience : 10 - 15 years
Job Location : Halol
Department : Process Engineering Manager
Qualification : 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.
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.
Implement 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
Technical 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.).

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