To lead and manage the complete assembly operations of HIP Turbine systems, ensuring precision assembly, adherence to stringent quality standards, on-time delivery, and continuous improvement in safety, productivity, and cost efficiency.
- Lead end-to-end assembly of HIP turbine modules including:
- Casings
- Rotors and shafts
- Blade assemblies
- Internal components and sealing systems
- Ensure compliance with engineering drawings, specifications, and tolerances
- Manage stage-wise assembly from sub-assembly to final build
- Ensure high-precision operations including:
- Rotor alignment and balancing readiness
- Bearing clearances and axial/radial positioning
- Critical torqueing and fastening sequences
- Oversee dimensional checks, runouts, and concentricity measurements
- Coordinate with metrology/inspection teams for critical verification
- Execute assembly schedules aligned with PPC and project timelines
- Monitor progress vs. plan and take corrective actions to avoid delays
- Identify and resolve bottlenecks in assembly sequence
- Optimize line balancing and takt time for HIP assembly
- Ensure zero-defect assembly by implementing stage inspections
- Coordinate for:
- Hydraulic & pressure testing
- Leak checks
- Functional verification of assembled turbine units
- Lead root cause analysis (RCA) and implement CAPA for failures
- Improve productivity (output per man-hour)
- Reduce rework, rejection, and cycle time losses
- Drive cost reduction through process improvements and waste elimination
- Monitor and control Cost of Poor Quality (COPQ)
- Ensure safe handling of heavy components, rotors, and high-pressure systems
- Conduct:
- Daily toolbox talks
- Risk assessments and safety audits
- Ensure proper usage of lifting tools, fixtures, and PPE
- Promote zero-LTI safety culture
- Implement Lean tools:
- 5S
- Kaizen
- Poka-Yoke
- Standard Work
- Drive cycle time reduction and process stability
- Develop and standardize best assembly practices
- Coordinate with:
- Design Engineering technical clarifications and deviations
- PPC schedules and priorities
- Supply Chain availability of critical components
- QA/QC inspections and clearances
- Support customer inspections and audits
- Lead assembly supervisors, engineers, and technicians
- Develop skill matrix for HIP turbine assembly competencies
- Train workforce in precision assembly techniques and safety practices
- Drive accountability, discipline, and performance culture
- Ensure availability and upkeep of:
- Specialized HIP assembly fixtures
- Alignment tools and dial gauges
- Torque tools and hydraulic equipment
- Work with maintenance for preventive maintenance and uptime improvement
- Maintain:
- Assembly records and check sheets
- Inspection and test reports
- Deviation and NCR records
- Track and present KPIs in daily/weekly reviews
- On-Time Delivery (OTD) for HIP turbines
- Assembly Cycle Time
- Alignment / clearance deviation levels
- Rework and rejection rate
- Productivity (Man-hour efficiency)
- Safety (Zero LTI)
- COPQ reduction
