About the Client - UK Based MNC into the manufacturing of Battery Charging Systems

Position Summary:

Reporting to the Director of Supply Chain, and working with Client's Contract Manufacturer (CM), the Manufacturing and Quality Engineer Manager will implement highly efficient and effective processes to manage:

- CM activities in India for quality and manufacturing engineering

- CM based Production and Material Control (PMC) activities

- SA (Schedule Attainment) including increases in line capacity, First Pass Yield and Uptime

- PPOH (Part Per Operator Hour) including increases in labour efficiency.

- OTD (On Time Delivery) tracking improvement, FPY, FAI and PPAP

- Drive efficiencies in the product manufacturing requirements and UPH

- Drive Manufacturing Process qualification/validations for any change introduced during and after product launch.

- Tier 2 supplier quality management

- Manufacturing quality improvement resulting in PPM reduction.

- Manage all factory quality issue, 8D and Failure issues.

This role is also responsible for ensuring that client's products are designed in a manner that is optimal for manufacturing. The Manager will continuously identify and champion improvements to existing products and manufacturing processes as required.

This position will be based in Manesar, India.

Specific Duties:

- Works closely with CM to move production lines from China to India and establish a stable manufacturing process in CM plants in India.

- Proactively identifies where Client's products could be better optimized for manufacture and assembly.

- Takes a lead role in driving identified requirements into the development and continuous improvement of manufactured products.

- Leads and reviews, Product Flow Chart(PFC), Production Failure Mode Effects Analysis (PFMEA) and Control Plan creation and updates (with supplier participation)

- Creates process flow charts for manufacturing and/or rework activities and develops critical manufacturing process.

- Regularly conduct physical Control plan audit on CM production lines and Tier 2 localized supply chain. Report audit findings.

- Develops work instructions for manufacturing and rework activities. Supports maintenance of PLM system for required products.

- Creates equipment requirements for production, assembly, and testing processes.

- Works with CM for production layout design

- Solves manufacturing issues on site with CM and implements new manufacturing process trail runs with the CM.

- Ensures Engineering Changes are implemented at the CM.

- Ensures that equipment and processes are being developed on time, on budget and to the required quality standards.

- Ensures that all assembly processes operate within lean manufacturing principles such as Value Stream Mapping, 5S, Kaizen, Kanban, poka-yoke etc. Reinforces TPM, standardized work and JI training in CM by regular auditing practices.

- Identifies manufacturing process improvements at the CM and the tiered supplier base and provides detailed cost benefit analysis to allow senior level evaluation and approval.

- Calculates and provides estimates and quotations for manufacturing (tooling, assembly, and manufacturing test equipment) to Operations leadership.

- Responsible for the Design for Manufacture and Assembly (DFMA) activities within his/her given brief.

- Conducts supplier development activities for localization as required.

- Performs special projects as required in support of departmental objectives.

- Manages orders through production and monitors factory performance for production completion and OTD.

- Coordinates product Engineering change orders, PCN, FAI activity.

Requirements:

- A minimum of 8+ years' experience as a Manufacturing Engineer in a high-volume manufacturing environment combined with a bachelor's degree, or equivalent, in Manufacturing Engineering or a relevant discipline such as Electronics Engineering or Mechanical Engineering

In-depth knowledge of the manufacture and assembly of power electronics products including:

- Lean manufacture of components and final product assembly

- Surface Mounting Technology / Through Hole Printed Circuit Board Assembly (PCBA) techniques

- Inductor/transformer manufacture

- Cable harness manufacture

- Custom mechanical assembly processes and equipment development

- In-process, end of line and out of box testing techniques

- Best practice knowledge of key supporting processes such as conformal coat, crimping, potting etc.

- Experience taking at least one project through manufacturing launch plus at least one year of subsequent production.

- Experience in DFMA techniques and participating on a product development team from inception through to manufacturing launch including evidence of the incorporating DFMA into the design.

- Knowledge of Bill of Materials (BOM), Engineering Change and Deviation practices

- Knowledge of Lean Manufacturing, Production System and Total Preventive Maintenance

- Knowledge and execution experience of APQP, PPAP, PFMEA, Control Plans, Process Flow, Process Capability and SPC

- Hands on experience of assembly jig/fixture for mass production

- Good project planning skills and a willingness to accept responsibility and to deliver to targets, showing perseverance to overcome obstacles.

- Ability to produce succinct reports/presentations to communicate the status of assigned projects and tasks.

- Familiarity with ISO/IATF16949 and ISO 9001 requirements

- Effective verbal and written communication skills in Hindi and English

- Must be independent, self-directed, an excellent team player with advanced team facilitation skills.

- Must be able to travel internationally.

- Must be available to be at the factory minimum of 3 days per week. Work from home required.

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