Lead Manufacturing Specialist - Process Engineer for Turbine Blades

Powerstatic Solutions India Private Limited; Sanand; On-site; INR 1,400,000 - 2,100,000; Full time

Job summary

Arabelle Solutions seeks a Lead Process Engineer to define manufacturing processes for turbine blades on fully automated CNC and robotics lines. You will develop process plans, specifications, and repair instructions, while leading PFMEA reviews and operator training.

Responsibilities include coordinating with tooling and NC programming teams, driving LEAN improvements, and ensuring on-time delivery with cost control. Candidates with 10+ years in turbine blade processes are preferred.

Qualifications

• BE/BTech/Diploma in Mechanical or Production with relevant experience.
• Strong capability in process planning and PFMEA development.
• Experience in turbine blade manufacturing or heavy machining is preferred.

Responsibilities

• Define process for manufacturing turbine blades in automated CNC and robotics lines.
• Prepare and generate manufacturing documentation: process plans, specs, drawings.
• Lead PFMEA reviews, MOP development, and operator skill upgrades.
• Drive cost reduction and continuous improvement initiatives across the line.

Skills

Process engineering

Lean Six Sigma

Root cause analysis

Team leadership

Education

BE/BTech/Diploma Mechanical/Production

Tools

NC programming

5-axis machining

MOP & PFMEA

Job description

Join us and work with global teams to support global customers ! At Arabelle Solutions, we have team members of more than 49 nationalities spread across 16 countries. At Arabelle Solutions, we know diversity makes teams and business stronger. Arabelle Solutions is a leading provider of nuclear turbine island technology and services. A third of the world's nuclear power plants rely on our technologies and services. Our innovative solutions and highly skilled teams energize the world with reliable, low-carbon electricity - critical for a sustainable future. With a heritage going back to the industry's early days, our expertise is built on continuous design innovation, manufacturing world-class turbine island technology and providing essential services to maintain, maximize and extend the lifetime of nuclear power plants across Europe, Asia and Africa. Our technologies range from the world's most powerful steam turbine in operation to modular designs optimized for SMRs, as well as generators, pumps, heat-exchangers, controls systems and cyber security. Arabelle Solutions has around 3,300 employees working across 16 countries. Arabelle Solutions believes that investing in employee development is key to our success. Our culture of learning focuses on developing our people and promoting the skills for the future. Thrive in a supportive work culture that is committed to continuous learning.

Responsibilities

• To define process for manufacturing of various turbine blades in fully automated CNC machining or blade shop and robotics production line, ensuring high precision, productivity, and safety performance. This role focuses on achieving first time right quality, continuous process optimization, improve lead time of machining, ensure Proper PFMEA & control plans are put in place.
• The Lead Process Engineer is responsible for preparation of various MPP & PFMEA get is reviewd from process expert & product owners. Define detailed MOP for producing various turbine blades, work with tooling & NC Programming teams. Work with production on skill upgradation of varoius operators & implement methods to ensure first time right quality.
• Prepare, develop, and generate all manufacturing documentation including, but not limited to process planning, method specification, process specification, repair instruction, drawing.
• Provide technical advice, engineering evaluation, and disposition to repair process and operation, including process troubleshooting and root cause analysis.
• Provide Qualification for Component Process
• Prepare new repair process development, 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 Plan, Engineering documentation & operator training.
• Coordinate with a team of individual contributors by establishing appropriate work plans and priorities consistent with engineering goals.
• Work with management to assign, perform, oversee, and schedule work tasks and meet 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 contriving new product / services introduction (NPI) Act as liaison with Repair Technology CoE to develop and implement new repair processes.
• Handle all customer complaints and recommend / perform resolutions as appropriate. Liaise with other department engineers for support / re-deployment of manpower and machine resources for internal sub-contract work
• Develop the best manufacturing practice in accordance with the customer CTQs Participate on Global Component Teams to drive productivity / standardization.
• Drive continuous process improvement through LEAN - Six Sigma.
• Participate on Environment Health & Safety Compliance
• Conduct Internal Audit according to ISO: 9001
• Accept other assignment based on Company Requirement
• Work on cycle time and cost reduction program for all kinds of repair work including in-house and on-site work.

Key Performance Indicators

• EHS and Lean
• On Time Delivery
• COPQ (Cost of Poor Quality) control
• New product qualification
• Root cause analysis & Risk assessment
• Process improvement

Desired Skill set

• Excellent process engineering capabilities and analytical skills.
• Thorough knowledge of heavy machining and assembly processes, Know how of steam turbine is beneficial.
• Key Assembly & Testing process – ITB Blading , RTB Blading (OEM & OOEM Design) for Rotor as well as Stationary Parts i.e Blade carrier , Inner Casing Diaphragm etc , Module Assembly for HP, IP & LP Module , Small IST Turbine , Nuclear HIP Turbine , Valve Assembly , Bearing Pedestal Assembly, Hydraulic Test of the Casing ,Valve & Bearing Pedestal
• Key Machining Processes – Milling , Turning of Shroud , Basic Knowledge of NC Programming & Job Set up on Machine
• Key Blade Manufacturing Process – Blade Machining on 5 Axis Machine and 3 Axis Machine ; Understanding of Blade Drawings and KODATA File & Final Polishing Process of Blades
• Thorough understanding of Engineering Drawings, Standards and Specifications
• Strong EHS & quality focus
• Strong interpersonal and leadership skills
• Strong oral and written communication skills
• Ability to identify and implement cost reduction strategies based upon process improvements and experience.
• Ability to develop credibility with employees, manager, and peers
• High attention to detail and accuracy of every task and Anticipate the future risks or challenges in advance
• Vendor development skills for new products and processes.
• Demonstrated integrity – accept and adhere to high ethical, moral, and personal values in decisions, communications, and actions when dealing with others
• Resolves internal issues quickly to meet customer expectations
• Come up with the alternative approach while raising a problem or a challenge
• Able to work cross functional teams to generate customer solutions as the final goal

Required Qualifications

BE/BTech/Diploma in Mechanical /Production min 10 years of relevant experience – min 5-yearcore experience of process/method of trubune blades is added advantages.