Senior Engineer-Production and Testing

Job Summary

We are seeking an experienced Senior Engineer Production & Testing with 15+ years of hands-on experience in the manufacturing and testing of power and distribution transformers. The ideal candidate will own day-to-day shop-floor production and the transformer test bay, ensuring output meets production schedules, quality standards, and customer/third-party test requirements. The role demands strong practical command of the full manufacturing sequence and of routine, type, and special testing, along with close coordination with the design, quality, planning, and stores functions.

Key Responsibilities Production

• Plan, execute, and supervise daily shop-floor production across core cutting, coil winding, core-coil assembly, drying (vacuum/VPI), tanking, and final assembly, in line with the production schedule and released drawings.
• Interpret General Arrangement (GA), core, winding, and tank/fabrication drawings, GTPs, and process sheets released by the design office, and translate them into accurate shop-floor execution.
• Achieve daily and monthly production targets through effective manpower deployment, shift planning, and line balancing.
• Monitor in-process quality at each manufacturing stage and ensure adherence to work instructions, process parameters, and applicable IS/IEC standards.
• Coordinate with design, quality, production planning, stores, and procurement to ensure material availability, smooth WIP flow, and timely resolution of shop-floor bottlenecks.
• Drive productivity improvement, cycle-time reduction, and optimal utilisation of raw materials (CRGO, copper/aluminium conductors, insulation, oil), minimising scrap and rework.
• Implement and sustain 5S, Kaizen, housekeeping, and shop-floor safety practices.

Key Responsibilities Testing

• Plan and conduct routine, type, and special tests as per IS 2026 / IEC 60076 — including turns ratio, winding resistance, insulation resistance, no-load and load losses, impedance, temperature rise, applied/induced overvoltage, and impulse tests, as applicable to the plant range.
• Conduct routine and acceptance tests in the presence of third-party inspection agencies and customer witnesses (CPRI / third-party) — a priority requirement of this role.
• Operate and supervise the test bay, ensuring correct test setups, instrument readiness, and full compliance with test-safety protocols.
• Maintain calibration status, test records, and traceability for all measuring and test instruments.
• Prepare, review, and finalise test reports, ensuring conformity with GTP and customer specifications before dispatch clearance.
• Diagnose test failures, drive root-cause analysis with production and design, implement corrective/preventive action, and re-test.

Required Skills & Expertise

• Strong hands-on experience across the complete transformer manufacturing process — core cutting, coil winding, core-coil assembly, drying/VPI, tanking, and final assembly.
• In-depth practical knowledge of transformer testing — routine, type, and special tests, test-bay operation, and test instrumentation.
• Ability to read and interpret GA, core, winding, and tank/fabrication drawings, GTPs, and customer technical specifications.
• Sound working knowledge of relevant standards: IS 2026, IEC 60076, IS 1180, CBIP guidelines, and ANSI, as applicable.
• Good understanding of raw materials — CRGO steel, copper/aluminium conductors, insulation materials, and transformer oil.
• Strong analytical, troubleshooting, and root-cause-analysis skills for production and test-floor issues.
• Manpower management, shift planning, and production-planning capability.
• Familiarity with quality management systems (ISO) and shop-floor improvement tools (5S, Kaizen).
• Strong communication and cross-functional coordination skills (production, quality, testing, design, procurement).
• Leadership ability to guide shop-floor teams, technicians, and junior engineers.

Qualifications

• B.E. / B.Tech in Electrical Engineering (Mandatory); M.E./M.Tech or Diploma with extensive relevant experience considered.
• 15+ years of relevant experience in power/distribution transformer production and testing, with a significant portion in a factory/test-bay environment.
• Prior hands-on experience in a transformer manufacturing plant is strongly preferred.

Key Attributes

• Detail-oriented with strong ownership of production targets and test integrity.
• Comfortable working on the shop floor and in the test bay.
• Proactive, hands-on problem solver who performs under production timelines.
• Strong team player with the ability to lead technicians and mentor junior engineers.