Process Engineer

Lucas TVS; Chennai District; On-site; INR 800,000 - 1,200,000; Full time

Job summary

Lucas TVS is seeking a detail-oriented Process Development Engineer to design and optimize manufacturing processes for new products, validate process flows, and support NPI and pilot production. You will lead improvements in OEE, cycle times, line balance and material flow, and apply Lean, Kaizen and 5S to reduce waste and ensure quality.

This role requires collaboration with Quality, Production and R&D to implement CAPA, Poka-Yoke and process control methods across the plant.

Responsibilities

• Develop and establish manufacturing processes for new products.
• Review product drawings, specifications and process requirements.
• Conduct process feasibility studies and identify manufacturing constraints.
• Support new product introduction (NPI) and pilot production.
• Prepare and validate process flow, work instructions and standard operating procedures.
• Prepare and maintain Process Flow Diagrams (PFD), PFMEA, Control Plans and SOPs.
• Define process parameters, cycle time, manpower and equipment requirements.
• Develop line layouts and optimize material flow.
• Establish standard work and process control methods.
• Drive cycle-time reduction, line balancing and productivity improvement.
• Identify bottlenecks and implement corrective actions.
• Improve OEE, machine utilization and manpower productivity.
• Apply Lean Manufacturing, Kaizen, 5S and other continuous-improvement techniques.
• Reduce process losses, rejection, rework and material wastage.
• Analyze process-related quality issues using RCA, 5 Why, Fishbone, 8D and CAPA.
• Work closely with Quality, Production, Maintenance and R&D teams to resolve process issues.
• Implement mistake-proofing (Poka-Yoke) wherever applicable.
• Monitor process capability and ensure adherence to defined specifications.
• Support customer complaints and corrective/preventive actions related to manufacturing processes.
• Provide technical support to production teams for daily process-related issues.
• Monitor process parameters and ensure compliance with standard operating conditions.
• Support trial runs, process validation and mass-production stabilization.
• Train operators and production personnel on revised processes and work instructions.
• Coordinate with tooling, maintenance and equipment teams for process requirements.
• Develop specifications for jigs, fixtures, gauges and special-purpose machines.
• Participate in machine commissioning and process validation.
• Identify automation opportunities to improve productivity, quality and safety.
• Identify opportunities for cost reduction and value engineering.
• Optimize manpower, machine utilization, material consumption and cycle time.
• Support VA/VE initiatives and productivity improvement projects.
• Track savings generated through process improvement activities.
• Ensure processes comply with safety standards and company requirements.
• Identify process-related safety risks and implement corrective measures.
• Support risk assessments and safe operating procedures.
• Ensure compliance with applicable automotive quality systems and internal procedures.

Skills

OEE

Cycle Time

Line Balance Efficiency

Productivity

Process Rejection / PPM

Rework & Scrap

Process Capability (Cp/Cpk)

Kaizen / Cost Reduction

Downtime

First Pass Yield (FPY)

New Product Launch / NPI milestones

Process Audit Compliance

Customer Complaint / Quality Closure

Job description

1. New Product & Process Development

• Develop and establish manufacturing processes for new products.
• Review product drawings, specifications and process requirements.
• Conduct process feasibility studies and identify manufacturing constraints.
• Support new product introduction (NPI) and pilot production.
• Prepare and validate process flow, work instructions and standard operating procedures.

2. Process Planning & Documentation

• Prepare and maintain Process Flow Diagrams (PFD), PFMEA, Control Plans and SOPs.
• Define process parameters, cycle time, manpower and equipment requirements.
• Develop line layouts and optimize material flow.
• Establish standard work and process control methods.

3. Productivity & Process Improvement

• Drive cycle-time reduction, line balancing and productivity improvement.
• Identify bottlenecks and implement corrective actions.
• Improve OEE, machine utilization and manpower productivity.
• Apply Lean Manufacturing, Kaizen, 5S and other continuous-improvement techniques.
• Reduce process losses, rejection, rework and material wastage.

4. Quality & Problem Solving

• Analyze process-related quality issues using RCA, 5 Why, Fishbone, 8D and CAPA.
• Work closely with Quality, Production, Maintenance and R&D teams to resolve process issues.
• Implement mistake-proofing (Poka-Yoke) wherever applicable.
• Monitor process capability and ensure adherence to defined specifications.
• Support customer complaints and corrective/preventive actions related to manufacturing processes.

5. Production Support

• Provide technical support to production teams for daily process-related issues.
• Monitor process parameters and ensure compliance with standard operating conditions.
• Support trial runs, process validation and mass-production stabilization.
• Train operators and production personnel on revised processes and work instructions.

6. Tooling, Fixture & Equipment

• Coordinate with tooling, maintenance and equipment teams for process requirements.
• Develop specifications for jigs, fixtures, gauges and special-purpose machines.
• Participate in machine commissioning and process validation.
• Identify automation opportunities to improve productivity, quality and safety.

7. Cost & Efficiency Improvement

• Identify opportunities for cost reduction and value engineering.
• Optimize manpower, machine utilization, material consumption and cycle time.
• Support VA/VE initiatives and productivity improvement projects.
• Track savings generated through process improvement activities.

8. Safety & Compliance

• Ensure processes comply with safety standards and company requirements.
• Identify process-related safety risks and implement corrective measures.
• Support risk assessments and safe operating procedures.
• Ensure compliance with applicable automotive quality systems and internal procedures.

Key Skills

• OEE
• Cycle Time
• Line Balance Efficiency
• Productivity
• Process Rejection / PPM
• Rework & Scrap
• Process Capability (Cp/Cpk)
• Kaizen / Cost Reduction
• Downtime
• First Pass Yield (FPY)
• New Product Launch / NPI milestones
• Process Audit Compliance
• Customer Complaint / Quality Closure