Deputy Manager - Process Engineering

Company name : MTC India Rubber Metal Components Pvt. Ltd

Industry : Railways

Position : Deputy Manager - Process Engineering

Work location - Bommasandra Industrial Area, Bangalore

Working days - 6 days (Monday to Saturday)

Company summary :

MTC India Rubber Metal Components Pvt. Ltd is a specialized subsidiary of Wabtec Corporation that specialized in the design and manufacture of rubber-metal suspension systems for the railway sector. MTC is part of Wabtec Corporation, and currently has production plants in Spain (HQ), China, India and US.

Position Mission

• Facility Creation & Process Optimization: Drive greenfield/brownfield facility execution for new projects and

orchestrate continuous process improvements in existing Rubber-to-Metal bonded manufacturing setups.

• Capacity Enhancement: Actively identify bottlenecks and systematically scale up production line capacity to

consistently satisfy surging client delivery schedules.

• New Product Industrialization: Build, validate, and sign off on new fabrication processes; transform prototypes into

robust mass-production baselines.

• Cross-functional Synergy: Maintain close daily touchpoints with the Production floor to identify real-world

inefficiencies, evaluate cycle lags, and deploy modern process modifications.

• Assembly Architecture Validation: Oversee the creation, structuring, and empirical validation of downstream

mechanical assembly frameworks, securing seamless manufacturability and strict defect control.

• Standardized Documentation: Standardize advanced manufacturing playbooks including Process Data Sheets

(PDS), Operation Data Sheets (ODS), Assembly Instruction Sheets (AIS), and Process FMEA.

Key Responsibilities & Operational Pillars

1. Process Design, Validation & Implementation

• Develop, validate, and execute robust production and assembly architectures optimized to hit rigid Quality, Cost, and

Delivery (QCD) targets.

• Establish and dynamically update fundamental manufacturing files: Process Flow Diagrams (PFD), Control Plans,

Process FMEA (PFMEA), and Standard Operating Procedures (SOPs).

• Lead rigorous technology transfer activities (Transfer of Technology - TOT) received from overseas technical entities

(SISCO), adjusting variables for full local configuration and end-customer sign-off.

2. Continuous Improvement & Lean Engineering

• Instill a culture of structural efficiency by managing Lean, Kaizen, Value Engineering, and systematic waste

elimination roadmaps across complex assembly chains.

• Conduct structured work-measurement audits, including stop-watch time studies, method studies, and deep-dive

MOST analysis to optimize line balancing and eliminate hidden idle time.

• Architect and deploy physical mistakeproofing systems (Poka-Yoke), smart automation loops, digital tracking

systems, and Industry 4.0 data frameworks to drive asset optimization.

3. Capacity & Layout Engineering

• Formulate detailed machine/line capacity planning models and evaluate technical process baselines through

continuous Cp and Cpk capability studies.

• Iterate and draft plant blueprints, macro/micro material logistics flows, and high-efficiency workstation designs to

maximize throughput per square meter.

• Deliver clean capacity matrices and analytical operational constraints as strategic inputs into the sites Strategic Plan

(Strap) and Sales, Inventory, & Operations Planning (SIOP) cycles.

4. New Product Industrialization (NPI)

• Direct the Advanced Product Quality Planning (APQP) cycle from conceptual sourcing checkpoints up to stable serial

dispatch.

• Coordinate with strategic sourcing teams to finalize Make vs. Buy commercial models for new project assets, tooling,

and incoming components.

• Own the end-to-end operational launch of new mechanical assemblies, organizing stage allocations, lineside

balancing, and training plans for ramp-up verification.

5. Tooling, Automation & Line Setup

• Conceptualize, detail, and refine specialized jigs, fixtures, customized ergonomic assembly tools, and dedicated

conveyors.

• Resolve active floor issues via systematic root cause analysis, resolving tooling deformations, fixture misalignments,

or process variances to sustain a stable running state.

• Govern the structural setup of incoming production layout nodes: detailing conveyors, hardware integration, utility

tie-ins, and safety compliance checks.

6. CAPEX & Budgetary Management

• Enforce strict budgetary control over capital allocations reserved for fresh programmatic launches and facility

upgrades.

• Build bulletproof financial justifications and detailed Return on Investment (ROI) models to secure prompt executive

budget validations from executive leadership.

• Supervise the entire lifecycle of engineering asset acquisition: defining engineering procurement sheets, tracking

vendor construction, managing installation, and overseeing formal commissioning.

7. Daily Operational Support & Risk Mitigation

• Provide immediate diagnostic support for active floor exceptions escalated through the site's Quick Response Quality

Control (QRQC) tracks.

• Run continuous engineering audits covering First Article Inspections (FAI) and formal Measurement Systems

Analysis (MSA / Gage R&R;).

• Track technical process downtime data, identify Pareto trends, and enforce definitive corrective actions to slash

recurring scrap generation and cycle delays.