Job Requirements

This role is for heading the PED function of Movement plant. PED function is responsible for creating process routing for Movement components, identify & establish new manufacturing process, anchoring engg change request trials, carry out new materials, process trails, establish alternate, secondary production sources, analysis of competitor product on process & quality, analysis & action plans for Mkt return feedbacks.

External Interfaces·      Vendors – Materials, Tools, Special process manufacturing·      Testing Labs

Internal Interfaces·      R&D – Product design·      Movement Manufacturing shops·      Assembly (Internal customer)·      Sourcing·      Material Engineering·      Quality Function·      Subcontract team·      Planning

Job Requirements :

Education : B.E (Mechanical Engineering / Production Technology)

Relevant Experience : 12-15 yrs. industrial experience

Behavioural Skills :     

• Process improvements exploration & implementing best manufacturing practises·      
• Inclination towards research of new process and new materials for cost reduction & process flow smoothening·      
• Constantly benchmarking process / Mfg technology with external world especially in the field of Horology & Precision component manufacturing

Knowledge :   

• Engineering drawings, 2D / 3D software skills·      
• Material Science / Metallurgy,·      
• Manufacturing process knowledge·      
• Analysis / Simulation software knowledge·      
• Manufacturing practises – Lean, TQM, Six Sigma·      
• Tool, Die & Fixtures manufacturing

Expected Process Contribution :

• Process Outcome
• Performance Measure

Movement Mfg : Manufacturing process Improvement

1.     Process optimization – Cycle time / Std time revisit & identifying opportunities for improvement

2.     Mapping new process routing for streamlining the product (Component) flow

3.     Benchmarking similar precision industries for Process innovations & technologies

4.     Trouble shooting of process limitations & propose new methods / tooling solutions / secondary operations

·  Lead time reduction & Capacity optimization

·  Smooth flow, De-bottlenecking

·  Breakthrough improvements

·  Per day per machine output

·  Number of new processes

·  Cost of operations

Movement Mfg : Engineering solutions

1. Process optimization

2. Engineering solutions as alternates or improving efficiency on various secondary operations carried out after manufacturing operations (Deburring, chips removal, finish improvements)

·  Annual Process Reviews

·  Secondary process effort reduction & efficiency

·  Number of process improvements

·  Leadtime / Temp manpower reduction for secondary operations

Movement Mfg : Process documentation & Trials

1. Ensuring creation of strong Operational Procedure Sheet for each product drawing covering all dimensions, Process routing & controls, critical to quality (CTQ) checks etc

2. Documenting all versions of changes on product and reason for changing

3. Conducting trials for Process, Quality, delivery improvements and documenting the results & feedbacks and upgrading the product drawings

4. New components / movements – proof of concept (POC) prototyping – coordination with in-house POC cell. Establishing alternate sources for quick prototyping of precision machining operations

·  Product drawing to Operational control document

·  Process improvement trials

·  Quick POC

·  Number of OPS

·  Number of trials

·  Number of POC components produced – alternate source

Movement Mfg : Quality

1. Perform Root-cause-analysis for repeat defects based on subsequent stage customer feedback & market return feedback

2. Projects for Engineering change request, design upgradations – tracking of milestones,

3. Identify quality parameters for Treatment processes & establish proper SOPs

4. Establish SOPs for finish (Turning & Machining operations)

·  Completion of Mkt reduction initiatives

·  Completion of ECRs & documentation

·  Reduction in Mkt returns

·  Reduction in Quality feedbacks from Assembly (Subsequent stages)

Movement Mfg : Alternate source / Materials

1. Benchmarking with competitor product / precision Industries on the materials being used.

2. Finding Suitable sources of materials indigenous to avoid import dependency

3. Coordinating and carrying out the trials for alternate materials / alternate sources – Process establishment, tooling suitability etc

·  New Raw material sources

·  Alternate material establishment

·  Cost Savings through alternate raw materials / alternate sources

Movement Mfg : Preparation for Mass Mfg

1. Coordination with R&D, Tool design & Tool Mfg for Stamping tools design & mass production establishment

2. For New components, coordination with Mfg shops, Tool design & Tool Mfg for Jigs, fixtures, Gauges & sub Assembly tools

3. Incorporating Mfg Shop feedbacks after Proto trials on product drawing for mass manufacturing

·  New Stamping tools for mass mfg

·  Mass mfg of new movement / components

·  Number of new movement / new components taken for Mass Mfg

Process improvement, Material Science, Analysis software knowledge, Tool, Die & Fixture Manufacturing, Lean, TQM, Six sigma, Engineering Drawings 2D/3D software skills