Senior Process Engineer - Engine Components and Assembly

AM/DM- Process Engineer, Engine PU

Responsibilities & Key Deliverables

1. Process Design & Development

• Develop and document manufacturing processes for Engine Components (block, head) & Engine Assembly.
• Select appropriate machining tools, cutting parameters, fixtures, gauges, and process flow.
• Prepare process plans, PFMEA, Control Plans, SOPs, and Work Instructions.

2. New Product Introduction (NPI)

• Collaborate with Product Engineering for DFMEA reviews.
• Participate in proto builds and pilot production.
• Drive PPAP/APQP activities for new components.
• Ensure process readiness for SOP (Start of Production).

3. Process Optimization & Continuous Improvement

• Improve process capability, quality, and productivity using:
• Lean manufacturing
• Six Sigma methodologies
• Kaizen / Poka‑Yoke / SMED,
• 7QC tools,
• Reduce rework, scrap, and process variation.
• Implement cost-saving initiatives (cycle time reduction, tool optimization, automation).

4. Quality & Compliance

• Conduct root cause analysis using 7QC tools.
• Support internal and external audits.
• Monitor process quality parameters and implement corrective actions.

5. Tooling, Equipment & Technology Management

• Select cutting tools, fixtures, gauges, and equipment.
• Coordinate with suppliers for tooling trials and validation.
• Support maintenance teams for resolving equipment issues.
• Recommend and deploy automation, CNC upgrades, or new technologies.

6. Cross‑Functional Collaboration

• Work closely with Production, Quality, Product Engineering, Maintenance, Purchase, and Vendors.
• Support customer queries or complaints related to process performance.
• Lead technical discussions on machining feasibility and process capability.

Experience

5 to 10 years of experience to candidate in Engine aggregates machining or process engineering.

Qualifications

• B.E./ B. Tech in Mechanical Engineering, Production Engineering or Post Diploma in Tool Engineering,

Certifications in Lean/Six Sigma (Yellow/Green Belt preferred) & cutting tools training are added advantages.

Required Skills & Competencies

Technical Skills

• Strong knowledge of engine components and manufacturing  process.
• Proficiency in CNC machining, cycle time study, and cutting tool applications.
• Experience with GD&T, CAD models, and engineering drawings.
• Understanding of metallurgical properties and machining behavior.
• Familiarity with APQP, PPAP, FMEA, MSA, SPC.

Soft Skills

• Problem-solving mindset
• Analytical thinking & data-driven approach
• Strong communication and documentation skills

Ability to work in cross-functional teams

KPIs

• Process capability (Cp/Cpk),
• Rework & rejection reduction,
• Cycle time improvement & productivity,
• Tooling cost reduction,
• OEE improvement,
• Successful PPAP/APQP completion,
• DCP compilation,
• EN Management,
• Audit compliance

• Process capability (Cp/Cpk),
• Rework & rejection reduction,
• Cycle time improvement & productivity,
• Tooling cost reduction,
• OEE improvement,
• Successful PPAP/APQP completion,
• DCP compilation,
• EN Management,
• Audit compliance

Experience Level

Senior Level