Job description
Industrial Efficiency through continual improvements
- Identify process related issues through SIM meetings; study the down time trends. Define problem areas and identify root cause. Propose solutions to eliminate the root cause; implement and evaluate effectiveness. Update process documents by incorporating the changes. Continually look for ways and means of improving productivity. Implement idea schemes within defined area of work. Maintain Update MTM dataon continual basis, revisit in case of process changes on yearly basis
- Full
- Industrial efficiency,
- DLP
- Capacity realization
Launching of new product
- Receive the documents from industrial team for all new projects. Study, evaluate and identify improvement points if any; Incorporate them before launch of the product
- Full
- Product Launch report
Qualification of Benches
- Study the basic machine design. Study the performance of the machine by producing a minimum of entire range on that particular machine. Validate the products produced with the support of quality. Study the time taken for production; Qualify the machine based on the results of the above study and tenderizing the historical quality level data of same/similar product
- Full
- Benches report
Conducting LIS
- Conduct Line short run on the qualified machines to find the areas of improvements if any. Based on identified areas of improvement take corrective / preventive action, Implement the same as part of the system. Declare the suitability of lines and make them available for production
- Full
- Appropriate line suitability
Troubleshooting / Problem Solving on a daily basis
- On a daily basis get to know quality issues, inadvertent breakdowns/ down time like change over adjustments, safety ergonomic related issues in the lines. Understand the problem and suggest alternative solution to immediately address the problem and regain production. Discuss with other product lines if required to identify and implement possible solutions; Work towards providing long term solutions to arrest the reoccurrence of the problem
- Full
- Capacity Realization
Process capabilities
- Monitor and measure process capabilities periodically. Take action based on deviations from the quality, production, and supply chain ; Analyze the issues and improve the process; Take trials to revalidate the process and re-establish the process documents
- Full
- Run the process within acceptable process capability status
Capacity planning and manpower forecasting :
- Receive long term Demand forecast from marketing for the next 3 years; Review capacity quarter-wise and take action to ensure capacity availability to meet the peek demands as per requirements; Check the capacity for both in-house and subcontractor capacities. Identify bottlenecks if any and work on removing the bottlenecks; Organize and implement the production facilities required for new capacity or for improved quality. Estimate manpower requirements for new capacity and inform HR for manpower planning. Ensure implementation of increased capacity on time such that, peak market demands are met as per requirements.
- Full
- 30 % Excess Capacity
Implement ECNs (Engineering change notes)
- Receive ECNs from the technical department; Study and find out implications on the existing process; Change the process to suit the ECN requirements; Update the relevant database and documents at the workstation. Call for prequalification of the processes as required. Train the concerned operators / supervisors to implement the changes; Manage change effectively.
- Full
- Run the process within acceptable process capability status
Implementation of SPS
- Implement SPS in production and support functions with reference to lean procedures; Ensure optimization of production floor layouts. Understand LADM and ensure implementation of same; Ensure ergonomy and safety. Be Aware of TPM and make changes in process in line with TPM requirements; Ensure appropriate Methodology and optimization of Material providing and handling. Implement Poke yoke and FMEA where ever required.
- Partial
- Implementation of SPS audit score
Technology transfer from Projects
- Learn the process from the projects team. Participate in the implementation, validation and qualification of the processes. Take charge of all technology transfer documents including drawings, test methods SOPs. Train the production team in implementation of the processes; Prepare and provide commissioning reports to the projects, maintenance and finance team.
- Full
- Establish process and achieve desired industrial efficiency
Handle Transfer Projects
- Receive requirements from mother plant, define schedule for the projects; brief the projects with internal department like procurement, technical, logistics and production. Prepare samples and get validated. Support in preparation of product costing and logistics feasibility. Validate the process variability.
- Full
- Core Line Validation
SOP preparation and updations
- Adhere to the changes and improvement made
- Based on process changes update SOPs and define variant charts data regularly. Ensure training to the production team to implement changes
- Full
- Compliance
Annual Budget planning
- Make budget provision for equipments, consumables, tools and seek approval for the same. Follow the budget and ensure expenses made within budget limits
- Partial
- Adhering to Budget limits
- Prepare contingency plan by analyzing cost/lead time required in recreation/reviving of manufacturing facility in minimum possible time and least cost Full
