Process Planning Engineer

Lucas TVS; Chennai District; On-site; INR 700,000 - 1,200,000; Full time

Job summary

Lucas TVS in India seeks an experienced Manufacturing Process Engineer to design and optimize processes for auto electrical assemblies. You will plan lines, machines, and workflows with robust controls, develop tooling and PFMEA/Control Plans, and drive successful NPI launches from design release to SOP.

You will work across product design, tool design, production, and quality teams to enable rampups, ensure quality, and pursue continuous improvement through lean Kaizen practices.

Qualifications

• Experience with motor industry manufacturing processes (winding, tightening, pressing, assembly, testing).
• Proficient in creating/maintaining PFMEA, Control Plans, and SOPs.
• Skilled in time study, line balancing, capacity planning.
• Experience in tooling/fixture design and process validation.
• Familiar with lean, Kaizen, and continuous improvement.
• Knowledge of basic quality tools (7 QC tools, RCA, SPC).
• Ability to read/interprete engineering drawings and GD&T.
• Exposure to ERP/MES for production planning and tracking.
• Strong analytical and problem-solving with cross-functional coordination.
• Basic understanding of electrical components and motor principles.

Responsibilities

• Develop manufacturing processes and organize facilities for auto electrical product assemblies and components.
• Plan cycle times, assembly lines, machines, and process plants with robust controls and optimal manpower.
• Prepare PFDs, PFMEA, and Control Plans for new and existing products.
• Develop and validate tooling, fixtures, and gauges for mass production.
• Ensure smooth launch of new products from design release to SOP.
• Collaborate with design, tool design, production, and quality teams for successful launches and improvements.
• Drive continuous improvement for productivity, cost reduction, and quality.
• Support establishing manufacturing processes like winding, assembly, testing, and other processes.

Skills

Manufacturing processes

Process planning

PFMEA

Line balancing

Tooling/fixtures

NPI/launch

Continuous improvement

Quality tools

GD&T

ERP/MES

Engineering drawings

Cross-functional coordination

Electrical concepts

Job description

KEY RESPONSIBILITIES

• Develop manufacturing process and organizing facilities for Auto electrical product assemblies and components


• Arrive cycle time, planning of assy lines / machines / process plants with robust process controls with optimal manpower.


• Preparation of Process Flow Diagrams (PFD), PFMEA, and Control Plans for new and existing products


• Develop and validate tooling, fixtures, and gauges required for mass production


• Ensure smooth and flawless launch of new products (NPI) from design release to SOP


• Collaborate with Product design, Tool Design, Production, and quality teams for successful launch of New Products and improvement projects.


• Drive continuous improvement initiatives for productivity, cost reduction, and quality enhancement


• Support Establishing various manufacturing process like winding, assembly, testing, special processes, etc.,)

REQUIRED SKILLS

• Strong knowledge of manufacturing processes in motor industry (winding, tightening, pressing, assembly, testing, etc.,)


• Expertise in process planning tools (PFD, PFMEA, Control Plan, SOPs)


• Understanding of time study, line balancing, and capacity planning


• Experience in tooling/fixture design and process validation


• Familiarity with lean manufacturing, Kaizen, and continuous improvement practices


• Knowledge of quality tools (7 QC tools, Root Cause Analysis, SPC basics)


• Ability to read and interpret engineering drawings and GD&T


• Exposure to ERP / MES systems for production planning and tracking


• Strong analytical and problem-solving capability with cross-functional coordination


• Basic understanding of electrical components and motor working principles