Senior Process Engineer

Johnson Electric Group; Chennai District; On-site; INR 2,400,000 - 4,000,000; Full time

Job summary

Johnson Electric Group in Chennai invites a Technical Lead for motor assembly manufacturing processes. You will drive process design, NPI, quality, productivity and Lean improvements.

You will design end-to-end process architecture, lead NPIs from feasibility to SOP, prepare PFMEA, Control Plans, and support automation and Industry 4.0.

The role requires BE/BTech in Mechanical or Mechatronics, 5+ years in automotive manufacturing, and Six Sigma Green Belt; Black Belt preferred.

Qualifications

• BE/B.Tech in Mechanical or Mechatronics Engineering.
• 5+ years in motor assembly processes in automotive manufacturing.
• Six Sigma Green Belt mandatory; Black Belt preferred.
• Proficient PFMEA, Control Plan, PFD, PPAP, APQP, MSA, SPC and quality tools.
• Lean manufacturing and Kaizen experience required.

Responsibilities

• Design end-to-end process architecture and line layout.
• Lead NPI launches from feasibility to mass production.
• Prepare PFD, PFMEA, Control Plan, SOPs and work instructions.
• Lead DFM/DFA, capacity planning and line balancing.
• Drive OEE, Kaizen, SMED, TPM and VSM initiatives.
• Lead RCA, 8D, CAPA, problem-solving for quality issues.
• Own process validation and capability studies.
• Support automation and Industry 4.0 implementation.
• Lead cross-functional teams with R&D, Quality, Production, Maintenance.
• Mentor junior engineers and ensure safety/compliance.

Skills

Technical leadership

Problem solving

Project management

Cross-functional coordination

Six Sigma Green Belt

Education

B.E./ B.Tech in Mechanical / Mechatronics Engineering

Tools

AutoCAD

SolidWorks

Minitab/JMP

GD&T

Process simulation tools

Job description

Job Purpose:

Technical lead for motor assembly manufacturing processes, driving process design, NPI, quality, productivity, Lean improvement, and process optimization.

Key Responsibilities:

• Design end-to-end process architecture, station sequence, cycle time, line layout, material flow, and manpower planning.
• Lead NPI / new product launches from feasibility through trials, PPAP, SOP, and mass production stabilization.
• Prepare and maintain PFD, PFMEA, Control Plan, SOP, Work Instructions, process parameters, layouts, and Poka-Yoke.
• Lead DFM/DFA, process feasibility, capacity planning, line balancing, tooling and equipment validation.
• Drive OEE improvement, Kaizen, SMED, TPM, VSM, Lean Manufacturing, productivity and cost reduction initiatives.
• Lead RCA, 8D, CAPA, problem-solving and process improvement for quality and production issues.
• Own process validation, MSA/GR&R, Cpk, PPAP, Run-at-Rate and process capability studies.
• Support automation, vision systems, robotics, sensors, servo systems and Industry 4.0 implementation.
• Lead cross-functional teams involving R&D, Quality, Production, Maintenance, suppliers and equipment vendors.
• Mentor junior engineers and ensure process documentation, safety and audit compliance.

Required Experience & Skills:

• B.E./ B.Tech in Mechanical / Mechatronics Engineering.
• 814 years in automotive manufacturing, with 5+ years in motor assembly processes preferred.
• Strong expertise in Process Engineering, Manufacturing Engineering and Industrial Engineering.
• Expert knowledge of PFMEA, Control Plan, PFD, PPAP, APQP, MSA, SPC and Quality Tools.
• Advanced knowledge of Lean Manufacturing, Six Sigma, SMED, TPM, Kaizen, Poka-Yoke and VSM.
• Six Sigma Green Belt mandatory; Black Belt preferred.
• Knowledge of AutoCAD, SolidWorks, Minitab/JMP, GD&T and process simulation tools.
• Strong technical leadership, problem-solving, project management and cross-functional coordination skills.