Senior Manager - Project Execution - Controls & Robotics

Purpose of the Role:

Responsible for leading digital transformation initiatives across manufacturing operations through implementation of Industry 4.0 technologies, IIoT, MES integration, data analytics, AI/ML solutions, digital dashboards, and smart factory systems. The role focuses on improving productivity, quality, asset utilization, energy efficiency, and operational excellence through data-driven decision-making and advanced digital technologies. The role ensures timely project execution, supports continuous improvement initiatives, and delivers departmental objectives aligned with Technical Services and PVBU goals.

Job Responsibilities

Digital Transformation & Industry 4.0

• Lead planning and execution of Smart Factory and Industry 4.0 initiatives.
• Identify and deploy digital solutions across Press, BIW, Paint, Assembly and Utilities.
• Evaluate emerging technologies and benchmark best practices from global automotive OEMs.
• Drive plant digital maturity and continuous improvement programs.

Industrial Connectivity & Data Management

• Implement standardized machine connectivity and plant-wide data acquisition systems.
• Integrate PLCs, robots, welding controllers, utility systems and shop floor equipment with layer3 platforms.
• Deploy OPC-UA, MQTT, IIoT gateways, Edge devices and Historian solutions.
• Support OT-IT convergence and data standardization initiatives.

Manufacturing Intelligence & Analytics

• Develop real-time dashboards for OEE, Quality, Energy, Productivity and Maintenance KPIs.
• Implement automated reporting and data visualization solutions.
• Drive advanced analytics for process optimization and root cause analysis.
• Support plant leadership with actionable insights through data-driven reporting

AI, Computer Vision & Advanced Technologies

• Implement AI-based quality inspection and defect detection solutions.
• Develop predictive maintenance and asset-health monitoring applications.
• Drive computer vision and machine learning projects for manufacturing operations.
• Evaluate and deploy Generative AI use cases for engineering and operations.

Manufacturing Systems Integration

• Integrate MES, SCADA, ERP, Historian and Quality Management Systems.
• Support digitalization of workflows, traceability and production monitoring.
• Ensure secure and reliable data exchange between shopfloor and enterprise systems.
• Ensure compliance with OT cybersecurity standards and corporate guidelines.
• Maintain digital architecture, system documentation and engineering standards.
• Coordinate vendors, system integrators, FAT/SAT and project commissioning activities

Desired Candidate Profile

Education: BE/B. Tech in Electronics, Electrical, Instrumentation, Computer Science, Information Technology, Automation, Mechatronics or equivalent. Experience: 510 years of experience in Digital Manufacturing, Industry 4.0, Smart Factory, Automation, MES, Manufacturing Analytics or related domains within Automotive Manufacturing.

Skills & Competencies:

• Functional/Technical: Industry 4.0 and Smart Manufacturing Solutions, IIoT, Edge Computing and Industrial Connectivity, MES, SCADA and Historian Platforms, Power BI, Tableau, Grafana and SQL Databases, OPC-UA, MQTT, REST APIs and Kepware, AI/ML, Predictive Analytics and Computer Vision, OT-IT Integration and Data Architecture, Manufacturing KPI Systems (OEE, Quality, Energy), OT Cybersecurity and IEC 62443 Awareness, Project Execution and Vendor Management
• Behavioral: Strong Analytical & Problem-Solving Skills, Innovation & Continuous Improvement Mindset, Ownership and Accountability, Communication & Stakeholder Management, Cross-Functional Collaboration, Customer Focus and Result Orientation
• Leadership: Lead Digital Transformation Programs, Drive Technology Adoption Across Manufacturing, Strategic Thinking and Decision Making, Change Management and Team Development, Deliver Business Value Through Digital Initiatives