Lead Manufacturing Engineer - Assembly Process

Powerstatic Solutions India Private Limited; Sanand; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Powerstatic Solutions India Private Limited is seeking a Manufacturing Engineer in Sanand, Gujarat to establish and optimize manufacturing processes. The ideal candidate will have over 8 years of experience in heavy machining and assembly processes, alongside strong engineering capabilities and focus on continuous improvement.

Responsibilities include developing manufacturing documentation, driving Lean initiatives, and coordinating equipment installation. Strong interpersonal and communication skills are crucial for collaboration across teams. An ethical grounding and attention to detail are essential.

Qualifications

• Minimum 8 years of relevant experience, including at least 5 years in core heavy machining.
• Thorough knowledge of heavy machining and assembly processes; knowledge of steam turbines is beneficial.
• Ability to develop credibility with employees, managers, and peers.

Responsibilities

• Establish detailed manufacturing processes with lead factories.
• Drive continuous improvement and lean initiatives.
• Prepare and generate all manufacturing documentation.

Skills

Process engineering capabilities

Analytical skills

Knowledge of heavy machining

Interpersonal skills

Leadership skills

Communication skills

Attention to detail

Problem-solving skills

Customer-focus orientation

Education

BE/B.Tech/Diploma in Mechanical or Production

Tools

5-axis and 3-axis machines

NC programming

Job description

Responsibilities

• Establish the detailed manufacturing processes using experience and coordination with lead factories.
• Drive a culture of continuous improvement and lean initiatives.
• Prepare, develop, and generate all manufacturing documentation, including process planning, method specifications, process specifications, repair instructions, and drawings.
• Provide technical advice, engineering evaluation, and disposition for repair processes and operations, addressing process troubleshooting and root‑cause analysis.
• Develop and qualify new repair processes, start‑up, training, and implementation.
• Coordinate with a team for installation, start‑up, and commissioning of new equipment.
• Prepare and perform operator qualification and special process qualification, including repair process plans and engineering documentation.
• Establish work plans and priorities, ensuring alignment with engineering goals, and assign, perform, oversee, and schedule work tasks while meeting cost objectives.
• Assist in the effective utilization of available manpower and machine resources for all repair, overhaul, and servicing jobs in accordance with company policies and procedures.
• Assist in future plans and contribute to new product or service introduction (NPI).
• Liaise with Repair Technology CoE to develop and implement new repair processes.
• Handle all customer complaints and recommend or perform resolutions as appropriate.
• Liaise with other department engineers for support and re‑deployment of manpower and machine resources for internal subcontract work.
• Develop best manufacturing practices in accordance with customer CTQs.
• Participate on Global Component Teams to drive productivity and standardisation.
• Drive continuous process improvement through Lean and Six Sigma methodologies.
• Participate on Environmental Health & Safety compliance activities.
• Conduct internal audits according to ISO: 9001.
• Work on cycle‑time and cost‑reduction programmes for all types of repair work, including in‑house and on‑site work.

Key Performance Indicators

• EHS and Lean performance
• On‑time delivery
• Cost of Poor Quality (COPQ) control
• New product qualification
• Root cause analysis & risk assessment
• Process improvement impact

Qualifications

• BE/B.Tech/Diploma in Mechanical or Production.
• Minimum 8 years of relevant experience, including at least 5 years in core heavy machining and assembly processes.
• Excellent process engineering capabilities and analytical skills.
• Thorough knowledge of heavy machining and assembly processes; knowledge of steam turbines is beneficial.
• Strong knowledge of key assembly & testing processes, such as blade carrier, inner casing, diaphragm, module assembly for HP/IP/LP modules, small IST turbines, nuclear HIP turbines, valve and bearing pedestal assemblies, and hydraulic casing tests.
• Proficiency in key machining processes, including milling and turning of shrouds.
• Basic knowledge of NC programming and job set‑up on machines.
• Experience with blade manufacturing on 5‑axis and 3‑axis machines, understanding blade drawings, KODATA files, and final polishing processes.
• Strong understanding of engineering drawings, standards, and specifications.
• Strong EHS and quality focus.
• Strong interpersonal, leadership, and communication skills.
• Ability to identify and implement cost‑reduction strategies based on process improvements.
• Ability to develop credibility with employees, managers, and peers.
• High attention to detail and accuracy of every task.
• Vendor development skills for new products and processes.
• Demonstrated integrity and adherence to high ethical and moral values in decisions, communications, and actions.
• Capability to resolve internal issues quickly to meet customer expectations.
• Problem‑solving and customer‑focus orientation.
• Strong analytical and cross‑functional team collaboration skills.