Senior Engineer Manufacturing Engineering (Assembly)

Live Connections; Chennai District; On-site; INR 68,850,000 - 93,150,000; Full time

Job summary

BorgWarner Morse Systems India Pvt Ltd located in Tamil Nadu is seeking a Senior Engineer Manufacturing Engineering (Assembly) with extensive experience in Tier-1 automotive assembly. The role focuses on developing new assembly processes, automation, and tool design for product launches, while leading capital and startup budgets.

Responsibilities include implementing process improvements, troubleshooting PLC-controlled systems, and guiding cross-functional teams to ensure on-time delivery and

Qualifications

• 58 years of experience in Tier-1 automotive OEMs.
• Proven assembly manufacturing and automation expertise.
• Strong experience with process improvements and cost savings.

Responsibilities

• Develop new assembly processes, equipment, tooling, and process controls for new product launches.
• Design prototype tools for customer sample builds.
• Conduct manufacturing feasibility studies, capacity analysis, and RFQ evaluations.
• Manage capital expenditure, tooling, and startup budgets.
• Lead installation, commissioning, trials, and handover of new assembly equipment.
• Drive process improvements in productivity, quality, safety, and poka-yoke implementation.
• Support production and quality teams in resolving critical line stoppages and customer complaints.
• Troubleshoot and maintain PLC-controlled systems (Mitsubishi, Siemens, Omron, Allen Bradley)

Skills

Manufacturing Engineering

Assembly Process Development

PLC Troubleshooting

Automation

Cycle Time Study

OEE

Line Balancing

SMED

Kanban

Lean Manufacturing

PFMEA

MSA

SPC

Control Plans

Work Instructions

8D & 5 Why

PDCA

QC Tools

Root Cause Analysis

Six Sigma & CI

Cross-functional Team Coordination

Tools

Mitsubishi PLC

Siemens PLC

Omron PLC

Allen-Bradley PLC

Job description

Job Title: Senior Engineer Manufacturing Engineering (Assembly)

Location: Kakkalur, Tiruvallur, Tamil Nadu

Company: BorgWarner Morse Systems India Pvt Ltd

Experience: 58 Years

CTC: 810 LPA

Industry: Tier-1 Automotive OEM / Auto Components Manufacturing

Preferred Background

58 years of experience in Tier-1 Automotive OEM/Auto Component Manufacturing.Strong exposure to assembly manufacturing, automation, shop-floor practices, and process improvement initiatives.

Key Responsibilities

• Develop new assembly processes, equipment, tooling, and process controls for new product launches.
• Design and develop prototype tools for customer sample builds.
• Conduct manufacturing feasibility studies, capacity analysis, and RFQ evaluations.
• Manage capital expenditure, tooling, and startup budgets.
• Lead installation, commissioning, trials, and handover of new assembly equipment.
• Drive process improvements in productivity, quality (Scrap/PPM), safety, and poka-yoke implementation.
• Support production and quality teams in resolving critical line stoppages and customer complaints.
• Troubleshoot and maintain PLC-controlled systems (Mitsubishi, Siemens, Omron, Allen Bradley)

Required Skills

• Manufacturing Engineering, Assembly Process DevelopmentPLC Troubleshooting & AutomationCycle Time Study, OEE, Line Balancing, SMED, Kanban, Lean ManufacturingPFMEA, MSA, SPC, Control Plans, Work Instructions8D, 5 Why, PDCA, QC Tools, Root Cause AnalysisSix Sigma & Continuous ImprovementCross-functional Team Coordination .