Process Engineer

Role & responsibilities

1. Develop, validate, implement and continuously improve manufacturing processes for Lead-Acid battery production to achieve safety, quality, delivery, cost and productivity targets.

2. Lead pilot builds, process validation and production ramp-up while ensuring manufacturing readiness.

3. Establish and maintain process standards, SOPs, Work Instructions, Control Plans, PFMEA, Process Flow Diagrams and Standard Cycle Times

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4. Drive improvements in manufacturing KPIs, including:

• First Pass Yield (FPY)
• Productivity
• Line Efficiency (OLE/OEE)
• Manufacturing Capacity
• KAIZENs
• Process Capability

5. Analyze production losses and process variations using structured problem-solving tools such as Fishbone Diagram, Pareto Analysis, SPC and Root Cause Analysis (RCA) and implement sustainable corrective and preventive actions.

6. Lead process optimization initiatives to eliminate waste, reduce cycle time, improve throughput and enhance overall manufacturing efficiency through Lean Manufacturing and Kaizen initiatives.

7. Conduct process validation activities, including JFT, DMI, process capabilities and process qualification before any product or process release.

8. Coordinate with R&D, Quality, Production, Maintenance, Supply Chain and EHS teams to ensure smooth pilots and product industrialization.

9. Evaluate and implement process changes, engineering change requests (ECR/ECN), tooling improvements and automation opportunities.

10. Monitor manufacturing performance through daily, weekly and monthly KPI reviews,

identify gaps and drive timely closure of action plans.

11. Lead and monitor pilot activities by ensuring readiness, tracking observations, verifying action closure and facilitating successful transition to mass production.

12. Support capacity planning, line balancing, manpower optimization and layout improvements to meet business and customer demand.

13. Drive quality improvement initiatives to reduce defects, rework, rejection and warranty failures by analyzing IFR, FFR and field feedback

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14. Lead continuous improvement projects focused on productivity enhancement, cost reduction, material savings and process simplification.

15. Ensure compliance with Quality Management Systems, Environmental, Health & Safety (EHS) and statutory requirements.

16. Mentor and guide junior engineers, supervisors and shop-floor personnel on process standards, problem-solving methodologies and best manufacturing practices.

17. Prepare and present process performance reviews, project updates and manufacturing dashboards to management, highlighting achievements, risks and action plans.

18. Support internal and external quality audits and ensure timely closure of audit observations related to the Process Engineering function.

Drive manufacturing excellence by developing, validating and continuously improving Inverter manufacturing processes to achieve organizational targets for Safety, Quality, Delivery, Cost and Productivity (SQDCP). Key result areas include:

• New Product Introduction (NPI), pilot execution and process validation.
• Improvement of FPY, productivity, capacity and line efficiency.
• Process standardization, SOPs, PFMEA and Control Plan implementation.
• Root cause analysis, defect reduction and process capability enhancement.
• Kaizen, Lean and cost reduction initiatives.
• Cross-functional coordination to ensure timely pilot production, product industrialization and sustained manufacturing performance.
• Compliance with Quality Management Systems (QMS), EHS requirements and continuous monitoring of manufacturing KPIs.