Industrial Engineer

Varroc; Pune District; On-site; INR 700,000 - 1,000,000; Full time

Job summary

Varroc in Pune is seeking an experienced Industrial Engineer to lead process improvement programs and 5S implementation on the shop floor. You will drive debottlenecking projects, conduct line balancing, time studies, and capacity planning while maintaining standardized cycles and layouts.

The role involves coordinating with QA and production teams to reduce waste, enhance ergonomics, and support NPI initiatives.

Responsibilities

• Execute debottlenecking projects to improve production throughput.
• Analyze quality defects with QA teams and implement corrective and preventive actions.
• Prepare and implement PCRNs (Process Change Request Notes).
• Conduct process capability and process qualification studies.
• Improve productivity through:
• Low-cost automation
• Conveyorization
• Layout optimization
• Alternate process development
• Manpower reduction initiatives
• Identify cost-saving opportunities through alternate materials, tools, inserts, cutting oils, and process improvements.
• Drive material flow improvements and waste reduction initiatives.
• Improve workstation ergonomics and operator efficiency.
• Support continuous improvement projects to achieve operational excellence.
• Conduct line balancing studies and optimize manpower utilization.
• Perform MOST (Maynard Operation Sequence Technique) time studies.
• Establish standard cycle times for manufacturing operations.
• Prepare and maintain:
• Product-wise capacity sheets
• Cell-wise capacity sheets
• Production planning data
• Provide manpower deployment and estimation plans based on production requirements.
• Analyze current manufacturing processes and recommend productivity improvements.
• Develop and update shop floor layouts with necessary approvals.
• Monitor manufacturing efficiency and line utilization.
• Support new product introduction (NPI) activities through process studies and capacity assessment.
• Develop and update 5S standards, formats, and master plans.
• Prepare annual 5S audit schedules.
• Conduct monthly cross-functional audits.
• Monitor audit compliance and closure of audit observations.
• Compile and present section-wise audit reports.
• Organize 5S review meetings with Plant Head and functional teams.
• Prepare Minutes of Meeting (MoM) and action plans.
• Track action plan closure and effectiveness.
• Monitor plant-wide adherence to 5S standards.
• Support external audits and ensure compliance.
• Prepare and close Non-Conformities (NCs) identified during audits.

Job description

Key Responsibilities

1. Process Improvement & Cost Optimization

• Execute debottlenecking projects to improve production throughput.


• Analyze quality defects with QA teams and implement corrective and preventive actions.


• Prepare and implement PCRNs (Process Change Request Notes).


• Conduct process capability and process qualification studies.


• Improve productivity through:




• Low-cost automation


• Conveyorization


• Layout optimization


• Alternate process development


• Manpower reduction initiatives




• Identify cost-saving opportunities through alternate materials, tools, inserts, cutting oils, and process improvements.


• Drive material flow improvements and waste reduction initiatives.


• Improve workstation ergonomics and operator efficiency.


• Support continuous improvement projects to achieve operational excellence.

2. Industrial Engineering Activities

• Conduct line balancing studies and optimize manpower utilization.


• Perform MOST (Maynard Operation Sequence Technique) time studies.


• Establish standard cycle times for manufacturing operations.


• Prepare and maintain:




• Product-wise capacity sheets


• Cell-wise capacity sheets


• Production planning data




• Provide manpower deployment and estimation plans based on production requirements.


• Analyze current manufacturing processes and recommend productivity improvements.


• Develop and update shop floor layouts with necessary approvals.


• Monitor manufacturing efficiency and line utilization.


• Support new product introduction (NPI) activities through process studies and capacity assessment.

3. 5S Implementation & Audit Management

• Develop and update 5S standards, formats, and master plans.


• Prepare annual 5S audit schedules.


• Conduct monthly cross-functional audits.


• Monitor audit compliance and closure of audit observations.


• Compile and present section-wise audit reports.


• Organize 5S review meetings with Plant Head and functional teams.


• Prepare Minutes of Meeting (MoM) and action plans.


• Track action plan closure and effectiveness.


• Monitor plant-wide adherence to 5S standards.


• Support external audits and ensure compliance.


• Prepare and close Non-Conformities (NCs) identified during audits.