Industrial Engineer

Tata Semiconductor Assembly & Test (TSAT) is a greenfield venture of the Tata Group with expertise in manufacturing in IC & SMT Packages.

Tata Electronics (a wholly owned subsidiary of Tata Sons Pvt. Ltd.) is building Indias first AI-enabled state-of-the-art Semiconductor Packaging facility . This facility will produce chips for applications such as power management IC, display drivers, microcontrollers (MCU) and high-performance computing logic, addressing the growing demand in markets such as automotive, computing and data storage, wireless communications and artificial intelligence.

TSAT is a subsidiary of the Tata group. The Tata Group operates in more than 100 countries across six continents, with the mission 'To improve the quality of life of the communities we serve globally, through long term stakeholder value creation based on leadership with Trust.’

Job Description

Position Purpose

The Industrial Engineer (IE) is responsible for optimizing factory performance across Semiconductor Assembly, Packaging, Burn-In, and Test operations. The role focuses on capacity planning, productivity improvement, cycle time reduction, workforce optimization, factory layout planning, and cost management to support business growth and operational excellence. The position works closely with Production, Planning, Process Engineering, Equipment Engineering, Quality, and Supply Chain teams to maximize throughput, improve asset utilization, and achieve world-class operational performance.

Key Responsibilities

Capacity Planning & Factory Loading

• Develop short-term and long-term capacity plans for Assembly, Test, Burn-In, and Packing operations.
• Analyze machine, labor, and floor-space capacity to support customer demand.
• Perform bottleneck identification and constraint analysis.
• Evaluate capacity requirements for new business opportunities and production ramps.
• Recommend expansion plans, equipment investments, and manpower requirements.
• Prepare monthly and quarterly capacity outlooks for management review.
• Support Sales, Program Management, and Production Planning with accurate capacity assessments.

Productivity & Workforce Optimization

• Establish manpower standards and labour productivity targets.
• Conduct time studies, motion studies, and work measurement analyses.
• Develop standard labour hours and staffing models.
• Optimize shift patterns, operator allocation, and direct labour utilization.
• Drive productivity improvement initiatives through Lean Manufacturing principles.
• Identify opportunities to eliminate non-value-added activities and improve operational efficiency.
• Monitor labour efficiency and recommend corrective actions when targets are not achieved.

Cycle Time & Throughput Improvement

• Monitor end-to-end production cycle time across manufacturing operations.
• Analyse queue times, process delays, and workflow constraints.
• Develop action plans to improve throughput and reduce manufacturing lead time.
• Optimize Work-In-Process (WIP) levels and lot movement strategies.
• Support production prioritization and dispatching methodologies.
• Drive initiatives to improve factory output and delivery performance.

Equipment Utilization & OEE Management

• Monitor equipment utilization and Overall Equipment Effectiveness (OEE).
• Analyse downtime, idle time, changeover losses, and capacity losses.
• Support preventive maintenance optimization to improve equipment availability.
• Develop utilization improvement plans for critical production equipment.
• Provide data-driven recommendations for equipment procurement and capacity expansion.

Factory Layout & Space Planning

• Develop and maintain optimized factory layouts.
• Improve material flow and reduce transportation waste.
• Conduct line-balancing studies and workstation optimization.
• Support cleanroom utilization and expansion projects.
• Evaluate space requirements for new equipment installations.
• Improve warehouse, staging, and logistics flow efficiency.

Continuous Improvement & Lean Manufacturing

• Lead Lean, Six Sigma, and Kaizen projects.
• Conduct Value Stream Mapping (VSM) exercises.
• Implement 5S and visual management initiatives.
• Drive waste elimination and process simplification activities.
• Identify opportunities for automation and digitalization.
• Support annual cost reduction and productivity improvement programs.

Data Analytics & Performance Reporting

• Develop dashboards and performance reporting systems.
• Analyse production trends and operational KPIs.
• Support business decisions using statistical and analytical methods.
• Generate weekly and monthly operational performance reports.
• Create forecasting and simulation models for capacity planning.
• Utilize MES, ERP, and business intelligence tools for performance monitoring.

Cost Management & Business Support

• Drive manufacturing cost reduction initiatives.
• Analyse labour, equipment, and overhead cost drivers.
• Support annual operating plan (AOP) and budget development.
• Evaluate return on investment (ROI) for automation and capital projects.
• Monitor productivity savings and operational improvement benefits.
• Support customer quotation activities with cycle time and capacity analysis.

Key Deliverables

• Capacity Planning Models
• Productivity Improvement Roadmaps
• Labor Standards & Staffing Plans
• Factory Layout & Space Utilization Plans
• Cycle Time Reduction Programs
• OEE Improvement Reports
• Cost Reduction Initiatives
• KPI Dashboards and Management Reports
• Automation Business Cases
• Annual Productivity Plans

Qualifications

Education

• Bachelors degree in industrial engineering with OSAT or PCBA industries.
• Masters degree in industrial engineering or Operations Management preferred.

Experience

• 10+ years of Industrial Engineering experience in OSAT, Semiconductor, Electronics Manufacturing, or High-Volume Manufacturing environments.
• Strong understanding of Assembly, Test, Packaging, and Manufacturing Operations.
• Experience in Layout planning, capacity planning, productivity improvement, factory modelling, and operational excellence initiatives.

Technical Competencies

• Capacity Planning & Manufacturing Forecasting
• Industrial Engineering & Work Measurement
• Line Balancing & Labor Optimization
• OEE & Equipment Utilization Analysis
• Factory Layout & Facility Planning
• Lean Manufacturing & Six Sigma
• Cost Analysis & Productivity Improvement
• Semiconductor Packaging & Test Operations
• Data Analytics & Business Intelligence

Operational Excellence

• Lean Projects Completed
• Automation Opportunities Implemented
• Space Utilization Improvement
• Continuous Improvement Savings Achievement

Position Summary

The Industrial Engineer - OSAT is responsible for maximizing assembly and test factory performance through capacity planning, labor optimization, cycle time reduction, throughput improvement, factory layout planning, and operational excellence initiatives. The role delivers measurable improvements in productivity, cost, utilization, and delivery performance while supporting high-volume semiconductor packaging and test operations in a world-class manufacturing environment.