Process Engineer (Lapping & Polishing)

Motherson; Kanchipuram; On-site; INR 600,000 - 800,000; Full time

Job summary

Motherson is seeking a skilled Process Engineer in Kanchipuram, Tamil Nadu to develop and optimize surface finishing processes for high-precision components. The ideal candidate will have 5 to 9 years of experience in Surface Finishing, strong knowledge of manufacturing tools, and proven track record in achieving exceptional precision and quality standards.

The role involves collaboration with cross-functional teams to enhance production efficiency, implement Lean Manufacturing practices, and conduct process capability studies. A Bachelor's degree in Mechanical Engineering or related is required.

Qualifications

• 5 to 9 years of experience in Surface Finishing, Flat Polishing, and Manufacturing environments.
• Proven track record in achieving high precision (Ra 0.05 m, flatness 2 microns).
• Familiarity with ISO 9001, ISO 14001, and ISO 45001 standards.

Responsibilities

• Develop and optimize surface finishing processes.
• Design fixture tooling and slurry flow systems.
• Collaborate with teams for continuous improvement.

Skills

Surface finishing expertise

Statistical Process Control (SPC)

Lean Manufacturing Principles

Interpersonal and communication skills

Education

Bachelor of Engineering in Mechanical Engineering or related field

Tools

Profilometers

Coordinate Measuring Machines (CMMs)

Job description

Role & responsibilities

• To develop, stabilize, and optimize surface finishing and lapping processes for high-precision components, ensuring compliance with tight surface finish and flatness specifications, minimizing variation, and improving process capability across multiple work centres.
• Design and implement fixture tooling, lap plate conditioning routines, and slurry flow systems for repeatable material removal and also must have strong knowledge in using instruments like profilometers, interferometers, air gauges, flatness testers, and coordinate measuring machines (CMMs) for part validation.
• Expertise in strong understanding of surface finish parameters (Ra, Rz, etc.) and knowledge of abrasive types, slurry management, and consumables (abrasives, slurries, pads, plates, and tooling) used in finishing processes and Experience with inspection tools such as profilometers, surface roughness testers, CMMs, and gauge blocks. Collaborate with Quality, Production, and other Cross functional teams to validate processes and implement engineering changes in terms of Kaizen, Cost Saving, Man power Optimization and Poka Yoke effectively. Initiate the Continuous Improvement and Lean Manufacturing Principles to Streamline Production Process, Optimize the Work Flow, Eliminate the Waste and to Improve the Operational Efficiency. Expertise in conducting and document Process Capability studies (Cp, Cpk) and improve Overall Equipment Effectiveness (OEE) to maximize machine productivity and minimize downtime.
• Hands of Experience in conducting the experiment like DOE (Design of Experiments), SPC (Statistical Process Control) analysis, Waterfall Study and Data-driven yield improvements.
• Define Process Parameters, DFM, SOP & Other Documents supported for the Process, Consumables, Secondary Operations, and Qualifications.
• Expertise in preparing detailed Process Flow Diagrams (PFDs), Process Failure Mode and Effects Analysis (PFMEAs), and Control Plans (CPs) for effective process management and risk mitigation.
• Support Internal and External audits (Includes Customer Audit) by ensuring document traceability, calibration records, and compliance to documentation protocols.
• Continuously monitor and update key manufacturing performance metrics including OPP (Overall Process Performance), OEE (Overall Equipment Effectiveness), PPH (Parts Per Hour), FTQ (First Time Quality), tool and consumable usage, CPC (Cost Per Component), and scrap cost.

Preferred candidate profile

• Bachelor of Engineering degree in Mechanical Engineering, Manufacturing Engineering, or related field. Minimum 5 to maximum 9 years of experience in Surface Finishing, Flat Polishing, Hole Polishing, Wet Blasting in a Manufacturing environment.
• Experience in proven Track Record in Achieving Ra 0.05 m, Controlling flatness 2 microns, parallelism 3 microns and developing repeatable, statistically capable processes (Cp 1.33, Cpk 1.0) Familiarity with ISO 9001 / ISO 14001 / ISO 45001 (as applicable to industry).
• Excellent interpersonal and communication skills must influence and collaborate globally