Blade Process Engineer - Wind Turbine Manufacturing

Manager

About Business:

Adani Group: Adani Group is a diversified organisation in India comprising 10 publicly traded companies. It has created a world class logistics and utility infrastructure portfolio that has a pan-India presence. Adani Group is headquartered in Ahmedabad, in the state of Gujarat, India. Over the years, Adani Group has positioned itself to be the market leader in its logistics and energy businesses focusing on large scale infrastructure development in India with O&M practices benchmarked to global standards. With four IG rated businesses, it is the only Infrastructure Investment Grade issuer in India.

Wind Turbine Generator (WTG): Adani Wind Turbine Generators (WTG) is a leading player in the renewable energy sector, specializing in the design, manufacturing, and installation of high-performance wind turbine systems. With a commitment to sustainability, Adani WTGs deliver efficient and reliable energy solutions, contributing to clean power generation across global markets.

Job Purpose:

The Blade Process Engineer is responsible for designing and optimizing blade manufacturing processes, ensuring they meet production efficiency and quality standards. This role involves developing detailed work instructions, monitoring process parameters, and implementing corrective actions to address production deviations. The Process Engineer supports troubleshooting efforts on the shop floor, participates in root cause analysis of process-related defects, and collaborates with material engineers to validate the integration of new materials into existing processes. This position plays a key role in maintaining compliance with industry standards, documenting process changes, and contributing to continuous improvement efforts to enhance blade quality and reduce production costs.

Process Design and Implementation

• Design and implement blade manufacturing processes, including resin infusion, layup, and curing, using advanced process control techniques to ensure consistency and quality.
• Develop detailed work instructions and process flow diagrams to guide production teams in executing blade manufacturing tasks effectively.

Production Optimization and Troubleshooting

• Optimize production processes by analyzing cycle times, material usage, and labor efficiency, implementing changes to reduce waste and improve throughput.
• Conduct on-site troubleshooting of process deviations, including resin flow issues and curing irregularities, to minimize downtime and maintain production targets.

Quality Control and Process Monitoring

• Establish in-process monitoring systems to track key parameters such as temperature, pressure, and resin flow during blade production, ensuring compliance with design standards.
• Perform root cause analysis on process-related defects, utilizing data-driven techniques to implement corrective actions and enhance process stability.

Site Troubleshooting and Root Cause Analysis

• Participate in site troubleshooting and corrective actions for blade process issues, conducting on-the-ground analysis to resolve quality or operational challenges.
• Use advanced diagnostic tools to identify process inefficiencies and implement solutions to improve production reliability.

Process Documentation and Standards Compliance

• Maintain up-to-date documentation of process specifications, standard operating procedures (SOPs), and quality control checklists to ensure compliance with industry and company standards.
• Ensure all processes adhere to regulatory requirements, including health, safety, and environmental standards.

Material Integration and Testing

• Work closely with the Blade Material Engineer to test and validate new materials in the production environment, ensuring seamless integration with existing processes.
• Conduct trials of alternative resin systems or composite materials, analyzing results to determine feasibility and performance impact.

Adherence to Policies and Ethical Considerations

• Adhere to organizational policies and ethical standards in all engineering activities, ensuring transparency and integrity in process design and execution.
• Participate in training on corporate policies, ethics, and compliance to maintain high professional standards.

Continuous Improvement and Innovation

• Proactively seek opportunities for process improvements, engaging in Kaizen events and Lean initiatives to enhance production efficiency and reduce costs.
• Stay updated on the latest advancements in blade manufacturing technologies, incorporating best practices and innovations into the process design.

Key Stakeholders - Internal:

• Blade Material Engineer
• Lead - Blade Process Engineering
• Manufacturing Teams
• QA Teams

Key Stakeholders - External:

• Composite Material Suppliers
• Tooling Suppliers

 

Educational Background:

• BE in Mechanical Engineering or related field.

Work Experience:

• 5+ years designing blade manufacturing processes, with a focus on optimizing production flow and implementing corrective actions for defects.

Industry Knowledge:

• Proficient in process monitoring, root cause analysis, and integrating new materials into existing production lines for enhanced blade quality.

Experience Level

Mid Level