Manufacturing Engineering Professional

Blue Star; Tada; On-site; INR 1,500,000 - 2,500,000; Full time

Job summary

Blue Star is seeking a senior Lead Manufacturing Engineering and MES specialist to drive process development, optimization, automation, and OEE improvement. You will ensure safe, reliable, cost-effective manufacturing through robust process engineering and data-driven improvement, collaborating with Production, Quality, RD, Maintenance and IT.

The role also covers MES governance, automation projects and lean manufacturing initiatives to raise efficiency, yield and throughput across the plant.

Qualifications

• Lead manufacturing engineering and MES initiatives across development and optimization.
• Collaborate with Production, Quality, RD, Maintenance and IT to achieve objectives.
• Drive continuous improvement and data-driven manufacturing practices.

Responsibilities

• Develop and improve manufacturing processes for existing products, ensuring quality, safety, reliability and process stability.
• Create and maintain Process Flow Charts, PFC/PFD, SOPs, Work Instructions, Control Plans and other manufacturing documentation.
• Define process parameters, standard work and manufacturing controls.
• Conduct process validation and establish robust manufacturing processes.
• Improve process capability, OEE, yield, cycle time, equipment utilization and manufacturing cost.
• Develop and implement tooling, fixtures, gauges, jigs and Poka-Yoke solutions.
• Support Production, Quality and RD teams in resolving process, manufacturability and product-related manufacturing issues.
• Conduct root-cause analysis and implement corrective and preventive actions for recurring manufacturing problems.
• Lead MES operation and continuous improvement.
• Define MES processes, routing and production workflows.
• Manage MES master data including product, process, routing, BOM and production-related information as applicable.
• Implement electronic work instructions, digital SOPs and process controls through MES.
• Establish real-time production data collection for output, rejection, downtime, cycle time, process status and operator activity.
• Establish product and process traceability from raw material through finished goods.
• Support integration of MES with ERP/SAP, machines, PLCs, testers, scanners and other shop-floor systems.
• Monitor MES data accuracy and ensure alignment between actual shop-floor processes and system transactions.
• Develop MES dashboards and reports for OEE, downtime, rejection, FPY and manufacturing performance.
• Analyze MES data to identify process losses, equipment issues and opportunities for improvement.
• Coordinate with IT, MES developers and external system integrators for troubleshooting, enhancements and system upgrades.
• Conduct MES user training, UAT, system validation and implementation support.
• Ensure controlled MES changes through ECN/change-management procedures.

Skills

Process Engineering

MES

Automation

OEE

Lean Manufacturing

Process Improvement

Tools

SAP

ERP systems

MES

Job description

Role Purpose

Lead Manufacturing Engineering and MES activities covering process development, process optimization, automation, OEE improvement, manufacturing system digitalization and continuous improvement.

The role will ensure safe, reliable, efficient and cost-effective manufacturing processes through robust process engineering, MES utilization, automation and data-driven improvement. The position will work closely with Production, Quality, RD, Maintenance, IT and other cross-functional teams to achieve manufacturing objectives.

Key Areas

Process Engineering | MES | Automation | OEE | Lean Manufacturing | Process Improvement

Key Responsibilities Process Manufacturing Engineering

• 1. Develop and continuously improve manufacturing processes for existing products, ensuring quality, safety, reliability and process stability.
• 2. Develop and maintain Process Flow Charts, PFC/PFD, SOPs, Work Instructions, Control Plans and other manufacturing documentation.
• 3. Define process parameters, standard work and manufacturing controls.
• 4. Conduct process validation and establish robust manufacturing processes.
• 5. Improve process capability, OEE, yield, cycle time, equipment utilization and manufacturing cost.
• 6. Develop and implement tooling, fixtures, gauges, jigs and Poka-Yoke solutions.
• 7. Support Production, Quality and RD teams in resolving process, manufacturability and product-related manufacturing issues.
• 8. Conduct root-cause analysis and implement corrective and preventive actions for recurring manufacturing problems.

MES - Manufacturing Execution System

• 1. Lead and support the operation and continuous improvement of the Manufacturing Execution System (MES).
• 2. Define and maintain manufacturing processes, routing, operations, workstations and production workflows within MES.
• 3. Manage MES master data including product, process, routing, BOM and production-related information as applicable.
• 4. Implement electronic work instructions, digital SOPs and process controls through MES.
• 5. Establish real-time production data collection for output, rejection, downtime, cycle time, process status and operator activity.
• 6. Establish product and process traceability from raw material through finished goods.
• 7. Support integration of MES with ERP/SAP, machines, PLCs, testers, scanners and other shop-floor systems.
• 8. Monitor MES data accuracy and ensure alignment between actual shop-floor processes and system transactions.
• 9. Develop MES dashboards and reports for OEE, downtime, rejection, FPY and manufacturing performance.
• 10. Analyze MES data to identify process losses, equipment issues and opportunities for improvement.
• 11. Coordinate with IT, MES developers and external system integrators for troubleshooting, enhancements and system upgrades.
• 12. Conduct MES user training, UAT, system validation and implementation support.
• 13. Ensure controlled MES changes through ECN/change-management procedures.

Automation Process Improvement

• 1. Identify and implement automation and semi-automation opportunities to improve quality, safety and process efficiency.
• 2. Lead Low-Cost Automation (LCA), robotics, sensors, interlocks and automated inspection projects.
• 3. Implement Poka-Yoke and process-monitoring solutions to prevent manufacturing defects.
• 4. Reduce manual dependency, cycle time, scrap, rework and process losses through engineering improvements.
• 5. Improve material flow, workstation design, ergonomics and operator movement through process improvements.
• 6. Drive Kaizen and Lean Manufacturing projects with measurable quality, cost and process benefits.
• 7. Evaluate process simulation opportunities using tools such as FlexSim for process optimization.
• 8. Support Industry 4.0 and smart manufacturing initiatives through digital data collection and real-time monitoring.

OEE Equipment Performance

• 1. Monitor and improve OEE across manufacturing equipment…