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
Internal Interfaces
- Vendors – Materials, Tools, Special process manufacturing
- Testing Labs
- 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 Contributions
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
