Manufacturing Process Design, Senior Leader

Vertiv Energy; Mumbai; On-site; INR 3,500,000 - 6,000,000; Full time

Job summary

Vertiv Energy is seeking a Manager/Senior Leader of Manufacturing Process Design to architect production ecosystems and drive the Virtual-to-Physical transition for Power and Thermal products. You will bridge R&D and shop floor using high-fidelity DES and Full-Line Balancing to optimize lines before production.

You will lead NPI, design integration, DFM/DFA leadership, virtual commissioning, and continuous improvement across global plants, mentoring a team of engineers and ensuring a Right First

Qualifications

• 15+ years of hands-on experience in manufacturing process design for power products.
• Bachelor's degree in Industrial/Manufacturing Engineering or related field.
• Master's degree in Industrial & Systems Engineering or Data Analytics preferred; leadership/PM experience.
• Proven launch track record applying DFM/DFA and high-fidelity simulation modeling.
• CAD and advanced simulation tools proficiency (SolidWorks, AutoCAD, FlexSim/Arena/Simio/AnyLogic).
• Lean manufacturing expertise, Yamazumi, Kaizen, and waste reduction.

Responsibilities

• Lead NPI by integrating manufacturing constraints into product DNA before design freeze.
• Balance processes to takt time; neutralize bottlenecks and connect islands of automation.
• Translate Yamazumi data into DES models to stress-test production before launch.
• Lead DFM/DFA reviews to minimize ECOs post-launch.
• Oversee virtual commissioning and validation (IQ/OQ/PQ) for line layouts and equipment.
• Drive root cause analysis and continuous improvement using FMEA and Six Sigma.
• Coordinate cradle-to-grave lifecycle with global design centers and local plants.
• Mentor engineers in Yamazumi, DFM/DFA, and advanced manufacturing tech.

Skills

Discrete Event Simulation

Yamazumi modeling

Data analytics

Executive communication

Systems integration

Education

Bachelor's degree in Industrial/Manufacturing Engineering

Master's degree in Industrial & Systems Engineering or Data Analytics

Tools

SOLIDWORKS

AutoCAD

FlexSim/Arena/Simio/AnyLogic

Power BI/Tableau

Job description

POSITION SUMMARY

• Vertiv is seeking a Manager / Senior Leader of Manufacturing Process Design to act as the lead architect of our production ecosystems. In this role, you will be responsible for the "Virtual-to-Physical" transition of our Power and Thermal products, serving as the primary bridge between R&D and the shop floor. By integrating Full-Line Balancing with high-fidelity Discrete Event Simulation (DES), you will ensure that our manufacturing lines are mathematically optimized for maximum efficiency long before the start of production. This role requires a blend of deep industrial engineering expertise, leadership acumen, and advanced data modeling to drive a "Right First Time" global launch strategy.

RESPONSIBILITIES

• Up-Front Design Integration: Lead the New Product Introduction (NPI) process by collaborating with R&D at the earliest design stages. Ensure manufacturing constraints, plant capabilities, and automation requirements are integrated into the product DNA before design freeze.
• Synchronized Process Design & Bottleneck Neutralization: Drive operational excellence through rigorous Yamazumi modeling, ensuring all manufacturing processes are perfectly balanced to Takt time. By neutralizing bottlenecks and bridging disconnected "islands of automation, " you will create a seamless, synchronized flow that eliminates process unevenness and waste, minimizing WIP and maximizing plant-wide throughput.
• Data-Driven Simulation (DES): Oversee the translation of Yamazumi work-content data and line-balancing profiles into Discrete Event Simulation models. Capture granular process data including MTBF, MTTR, and precise step-level cycle times to virtually "stress test" the production environment and validate throughput targets before physical implementation.
• Proactive DFM/DFA Leadership: Direct the execution of rigorous Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews. Act as the final gatekeeper for manufacturability, identifying assembly risks early to reduce engineering change orders (ECOs) post-launch.
• Virtual Commissioning & Validation: Utilize simulation tools to perform "What-If" analysis on proposed line layouts, accounting for variable demand and supply chain lags. Oversee the selection and validation (IQ/OQ/PQ) of manufacturing equipment specific to power electronics.
• Root Cause & Continuous Improvement: Lead root cause analysis for production issues using FMEA and Six Sigma. Establish a feedback loop where real-time plant floor data from BackEnd/ERP systems updates to feed into the simulation models for continuous optimization.
• Cross-Functional Launch Orchestration: Drive alignment between global design centers and local plant operations. Serve as the technical management lead during the "Cradle-to-Grave" lifecycle to ensure a flawless handoff to production teams.
• Team Leadership & Mentorship: Manage and mentor a team of engineers, fostering best practices in Yamazumi modeling, DFM/DFA, and advanced manufacturing technologies.

SKILLS

• Advanced Simulation Modeling: Expert-level capability in building and interpreting Discrete Event Simulation models to justify CAPEX and process changes.
• Industrial Engineering Toolkit: Mastery of Takt time analysis, Work Content Graphing, and Yamazumi work-balancing techniques.
• Executive Communication: Proficient in presenting complex simulation data, project timelines, and ROI projections to senior leadership.
• Systems Integration: Familiarity with ERP (SAP) and MES environments, with an understanding of how to structure "simulation-ready" manufacturing metadata.
• Bilingual Proficiency: Professional fluency in English and Spanish to facilitate global technical collaboration and cross-regional manufacturing support.

EDUCATION AND CERTIFICATIONS

• Degrees: Bachelor s degree in Industrial Engineering, Systems Engineering, Operations Research, Mechanical Engineering, Electrical Engineering, or Manufacturing Engineering.

• A Master s degree in Industrial & Systems Engineering (ISE) or Data Analytics is highly preferred. Experience: Minimum of 15+ years of hands-on experience in manufacturing process design for power products (UPS, DC power systems, or similar complex electronics), including experience in a leadership or project management capacity.
• Proven Launch Track Record: Demonstrated success applying DFM/DFA and high-fidelity simulation modeling to reduce manufacturing costs and improve reliability in high-volume, international environments.
• Software Proficiency: Expert in CAD software (SolidWorks, AutoCAD) and Advanced Simulation tools (e. g. , FlexSim, Arena, Simio, or AnyLogic). Proficiency in data visualization tools (Power BI/Tableau).
• Lean Mastery: Extensive experience with lean manufacturing principles, specifically Yamazumi (Work Balance) modeling, Kaizen events, and the mathematical removal of process waste.
• Certification (Preferred): Six Sigma Black Belt, Lean Manufacturing Certification, or Professional Engineering (PE) license.

PHYSICAL REQUIREMENTS

No Special Physical Requirements

ENVIRONMENTAL DEMANDS

No Special Requirements

TRAVEL TIME REQUIRED

• 25%