Head-IE (Six day week)

Varroc; Chhatrapati Sambhajinagar District; On-site; INR 2,500,000 - 4,200,000; Full time

Job summary

Varroc is seeking a Head of Industrial Engineering to lead the IE and continuous improvement initiatives at the plant. The role focuses on implementing manufacturing process changes, eliminating bottlenecks, and driving ME improvements across layout, equipment and workflow.

The candidate will oversee capacity planning, MOST studies, PFMEA reviews, and safe, timely execution of CI projects. Leadership and team development are key aspects of this position.

Responsibilities

• Lead Industrial Engineering and CI for the plant and drive process changes for ME improvement.
• Analyze bottlenecks, conduct MOST studies, and approve improvements with CI team.
• Guide tool design and fixture development; ensure timely in-house or outsourced manufacturing of tools.
• Support capacity planning, capacity utilization reviews, and manpower optimization on lines.
• Participate in recruitment and establish performance expectations for the team.

Job description

Role Title Head IE - Plant

1. JOB PURPOSE

Lead Industrial engineering and continuous improvement operations for the assigned plant; Ensure smooth

implementation of process changes for ME improvement;

1. Manufacturing Engineering Improvement

Analyze observed and anticipated issues; Provide ideas and brainstorm with the improvement central ME team on opportunities and scope for improvements in manufacturing processes through

process elimination, process merging, changes in layout etc.

Check feasibility of improvement ideas and estimate investments and timelines for execution.

Review the Process Change Request Note (PCRN) for proposed changes in manufacturing processes including aspects such as investments, feasibility, timelines, etc.; Share viewpoint on

the PCRN and submit to central Continuous Improvement (CI) team

Periodic review of PFMEA, poka-yoke and interlock list along with concerned engineer

Review process defect analysis and its adequacy for preventive/defective controls and get approval

from Plant Head/ Cluster Head -ME

Provide feedback and approval for capex investments on approved CI initiatives and process change impacts

2. Industrial engineering

Periodically review capacity sheet cellwise and product wise and get it approved from Cluster head -ME

Annual capacity planning and proposals for annual budgeting to Plant Head/ Cluster Head -ME

Monthly capacity utilization review and recommend actions to Plant Head/ Cluster Head -ME

Review & Plan capacity improvement for growth products by de-bottlenecking, automation etc.

Analyze and study identified bottlenecks in the line, direct team to conduct MOST (Time motion study) studies to further analyze the root cause; Review the outcome/ recommendations of the

MOST study; Approve and share the outcome with production for implementation; Keep track post implementation to check implementation success

Analyze current manpower utilization on lines and make recommendations on manpower requirements for various lines to optimize manpower

Review cycle time studies conducted by the team member to recommend scope for optimization

3. Tool design and tool room

Guide the team to prepare designs for fixtures and tools, based on product drawings and process design; Review tool and fixture designs prior to their manufacturing (inhouse tool room or outsourced) to ensure design is appropriate and meets all requirements

Post manufacturing, check the fixtures and tools to ensure manufacturing is in line with design.

Keep track of manufacturing of designed fixtures at inhouse tool room; Ensure high priorities projects are executed on time / as per priority.

Ensure adequate and timely manufacturing (inhouse/ outsourced) of tool and fixture spares to minimize break down time.

4. Team development

Participate in recruitment process to identify the right talent across positions within the function

Establish individual performance expectations and regularly review individual performance of the team.