Deputy Manager - Process Engineering

Mahindra and Mahindra Limited [Automotive and Farm Equipment Business]; Chakan; On-site; INR 900,000 - 1,400,000; Full time

Job summary

Mahindra and Mahindra Limited [Automotive and Farm Equipment Business] is hiring a BIW Manufacturing Engineer to perform formability analysis, CAE simulations, and develop robotic welding processes. You will coordinate with line builders, CMEs and PLCs to validate simulations during DAP and trials, ensuring zero collisions and optimal cycle times.

The role requires hands-on work with ABB/Fanuc/KUKA controls.

Qualifications

• Bachelors of Technology in Mechanical/Automobile.
• Diploma in Engineering in Mechanical/Automobile.
• 2–8 years of BIW Manufacturing, Production, Assembly experience.

Responsibilities

• Formability analysis of sheet metal parts and CAE simulations.
• Suggest counter measures for defects and interact with customer.
• Manufacturing feasibility study for new model introduction on existing line.
• Develop BIW process plans for manual and robotic welding lines.
• Create BIW robotic welding simulations and OLP in PS Team center.
• Generate standards and check sheets for simulation and OLP.
• Collaborate with CME, PLC and line builders for verification during DAP/trials.
• Installation, commissioning and post-SOP support for process and cycle time prove-out.
• Line layout, process flow, cycle time charts and RFQ prep for BIW sub-assembly.
• Study gun, equipment, fixtures and propose changes for manufacturability.
• Build station/cell/line in PS with required resources and verify kinematics.
• Create robot paths with zero collisions and optimize zoning.
• Coordinate with line builders to optimize robot paths and provide feedback.

Skills

Formability analysis

CAE simulation

Robotic welding

Line layout

Process optimization

OLP development

Robot path planning

Collision avoidance

Root cause analysis

Education

B.Tech Mechanical/Automobile

Diploma Mechanical/Automobile

Tools

Auto Form

Pam Stamp

Job description

Job Description:

Responsibilities & Key Deliverables

• Formability Analysis of Sheet Metal Parts.
• Simulation with CAE Software ( Auto Form / Pam Stamp). Suggesting Counter measures for the Defects.
• Interaction with customer and Concern Resolution. Manufacturing feasibility study for new model introduction in existing line.
• Develop BIW process plans for Manual and Robotic welding Lines.
• Develop BIW Robotic welding simulation cells and OLP in PS Team center / standalone.
• Generate standards and check sheets for Simulation and OLP through benchmarking and lessons learnt.
• Collaborate with CME process, PLC and Line builders for verification of Simulation and OLP during DAP and trials at suppliers.
• Installation and commissioning with post SOP support for Process and cycle time prove out.
• Line layout, Manufacturing process flow, Cycle time chart and RFQ preparation of BIW sub assembly.
• Do process study wrt gun, equipment, fixtures and suggest suitable changes in product to ensure first time right manufacturability.
• Build up the station/cell/line in PS by adding all relevant resources.
• Check for Gun reachability, apply all kinematics to relevant tools and create robot path with zero collision with basic tools.
• Generate Basic path (welding, tip dressing, etc) and zoning conditions to avoid any collision.
• Collaborate and Coordinate with Line builders to get the line simulation done and optimize the robot paths, robot zoning and again give feedback for any improvement required in design.
• Hands on experience of virtual controller such as- ABB / Fanuc / KUKA etc, generate the OLP with the cycle time accuracy of 99%.
• Find out root causes to achieve cycle time targets if not achieved.
• Ensure Zero error / collision / losses through continuous involvement with execution team.

Preferred Industries

Automotive Industry

Education Qualification

• Bachelors of Technology in Mechanical / Automobile
• Diploma in Engineering in Mechanical / Automobile

General Experience

2 to 8 years of relevant experience in BIW Manufacturing, Production, Assembly.