Industrial Engineer

Job Title: Industrial Engineer
Department: Industrial Engineering
Industry: Integrated Steel Plant / Steel Manufacturing

1. Job Purpose

To improve the productivity, efficiency, capacity utilization, manpower effectiveness and cost competitiveness of steel plant operations through systematic industrial engineering techniques, data analysis, work measurement, process optimization and continuous improvement initiatives.

2. Key Responsibilities

Manpower Planning & Productivity

• Develop and review manpower norms for production, maintenance and support functions.
• Conduct workload assessment and manpower requirement studies.
• Establish role-wise staffing norms based on workload, equipment capacity, operating hours and production targets.
• Identify opportunities for manpower optimization without compromising safety, quality or operational reliability.
• Monitor manpower productivity through appropriate KPIs.

Work Measurement & Process Improvement

• Conduct time studies, work sampling, method studies and productivity assessments.
• Develop standard work procedures and operating norms.
• Identify process bottlenecks, delays, idle time and non-value-added activities.
• Recommend process improvements to improve throughput and reduce operating costs.
• Benchmark productivity across departments, shifts, equipment and plants.

Production & Capacity Analysis

• Analyze production capacity versus actual output.
• Identify capacity constraints and opportunities for debottlenecking.
• Study equipment utilization, cycle time, turnaround time and process losses.
• Support production planning through capacity and resource analysis.

Cost Optimization

• Identify opportunities for reduction in manpower, energy, consumables and operational costs.
• Conduct cost-benefit analysis for process and productivity improvement projects.
• Support productivity-linked cost reduction initiatives.

Data Analysis & MIS

• Develop and maintain productivity and operational dashboards.
• Analyze production, manpower, utilization, downtime and efficiency data.
• Prepare periodic IE reports and management presentations.
• Establish and monitor departmental KPIs and productivity benchmarks.

Continuous Improvement

• Lead Lean Manufacturing, Kaizen, 5S, VSM and other continuous improvement initiatives.
• Identify and eliminate waste from manufacturing and support processes.
• Facilitate cross-functional improvement projects.
• Track benefits achieved from IE initiatives and ensure sustainability.

Digitalization & Automation

• Identify opportunities for digitalization and automation of manual processes.
• Use ERP/MES/data analytics tools for productivity and operational analysis.
• Develop data-driven models for manpower and capacity planning.

Project & Change Management

• Participate in new plant/project capacity studies.
• Evaluate manpower and resource requirements for new facilities and equipment.
• Support organizational restructuring and process redesign.
• Coordinate with Production, Maintenance, HR, Finance, Quality and Safety departments.

3. Required Qualifications

• B.E./B.Tech in Industrial Engineering, Mechanical Engineering, Production Engineering or related discipline.
• M.Tech/MBA/PG qualification in Industrial Engineering, Operations, Manufacturing or related field is desirable.
• Typically 5 - 10+ years of experience in industrial engineering, steel, heavy engineering, manufacturing or process industries.
• Strong knowledge of manufacturing processes and productivity improvement techniques.

4. Technical Competencies

• Industrial Engineering techniques
• Work measurement and time study
• Manpower planning and optimization
• Capacity planning
• Productivity analysis
• Lean Manufacturing
• Value Stream Mapping
• OEE and equipment utilization
• Process mapping
• Cost-benefit analysis
• Advanced Excel
• Power BI / data visualization
• ERP/MES systems
• Statistical analysis and data interpretation

5. Key Competencies

• Analytical and problem-solving ability
• Strong numerical and data-analysis skills
• Process-oriented approach
• Cross-functional coordination
• Project management
• Communication and presentation skills
• Ability to influence stakeholders
• Continuous improvement mindset
• Strong understanding of shop-floor operations

6. Ideal Candidate Profile

An ideal candidate should preferably from Steel Industry & capable of moving beyond traditional manpower calculation and act as an Operations Excellence / Productivity Improvement professional, linking manpower, production, capacity, equipment utilization and cost.