Senior Engineer

Role & responsibilities

1. To develop, stabilize, and optimize surface finishing and lapping processes for high precision components, ensuring compliance with tight surface finish and flatness specifications, minimizing variation, and improving process capability across multiple work centres.

2. Design and implement fixture tooling, lap plate conditioning routines, and slurry flow systems for repeatable material removal and also must have strong knowledge in using instruments like profilometers, interferometers, air gauges, flatness testers, and coordinate measuring machines (CMMs) for part validation.

3. Expertise in strong understanding of surface finish parameters (Ra, Rz, etc.) and knowledge of abrasive types, slurry management, and consumables (abrasives, slurries, pads, plates, and tooling) used in finishing processes and Experience with inspection tools such as profilometers, surface roughness testers, CMMs, and gauge blocks.

4. Collaborate with Quality, Production, and other Cross functional teams to validate processes and implement engineering changes in terms of Kaizen, Cost Saving, Man power Optimization and Poka Yoke effectively.

5. Initiate the Continuous Improvement and Lean Manufacturing Principles to Streamline Production Process, Optimize the Work Flow, Eliminate the Waste and to Improve the Operational Efficiency.

6. Expertise in conducting and document Process Capability studies (Cp, Cpk) and improve Overall Equipment Effectiveness (OEE) to maximize machine productivity and minimize downtime.

7. Hands of Experience in conducting the experiment like DOE (Design of Experiments), SPC (Statistical Process Control) analysis, Waterfall Study and Data-driven yield improvements.

8. Define Process Parameters, DFM, SOP & Other Documents supported for the Process, Consumables, Secondary Operations, and Qualifications.

9. Expertise in preparing detailed Process Flow Diagrams (PFDs), Process Failure Mode and Effects Analysis (PFMEAs), and Control Plans (CPs) for effective process management and risk mitigation.

10. Support Internal and External audits (Includes Customer Audit) by ensuring document traceability, calibration records, and compliance to documentation protocols.

11. Continuously monitor and update key manufacturing performance metrics including OPP (Overall Process Performance), OEE (Overall Equipment Effectiveness), PPH (Parts Per Hour), FTQ (First Time Quality), tool and consumable usage, CPC (Cost Per Component), and scrap cost.

Preferred candidate profile

1. Minimum 6 years of experience in Surface Finishing, Flat Polishing, Hole Polishing, Wet Blasting in a Manufacturing environment.

2. Experience in proven Track Record in Achieving Ra 0.05 m, Controlling flatness 2 microns, parallelism 3 microns and developing repeatable, statistically capable processes (Cp 1.33, Cpk 1.0)

3. Familiarity with ISO 9001 / ISO 14001 / ISO 45001 (as applicable to industry).