Sr. Engineer NPD - ME (Six day week)

Varroc; Chakan; On-site; INR 2,200,000 - 3,400,000; Full time

Job summary

Varroc is seeking a Sr. Engineer NPD - ME in its manufacturing division to lead new product development, industrialization, and process optimization for lighting products.

You will define assembly processes, establish production lines, and implement welding and gluing technologies to meet quality, productivity, and cost targets. Ideal candidates have 7–12 years in automotive or related manufacturing, strong experience in process design, line installation, and APQP documentation, and proficiency

Qualifications

• Bachelor's degree in Mechanical, Production, Industrial, Mechatronics, or related field.
• 7-12 years in Manufacturing/NPD Eng in automotive, lighting, electronics, or related manufacturing industry.
• Hands-on experience in assembly process development and line setup.

Responsibilities

• Lead manufacturing engineering activities for new lighting product introductions and localization.
• Define and develop manufacturing processes for lighting assemblies and sub-assemblies.
• Drive implementation and validation of various welding technologies.
• Develop, program, and optimize robotic gluing applications to ensure process consistency and quality.
• Prepare assembly line specifications including equipment requirements, cycle time calculations, layout concepts, tooling, and automation requirements.
• Lead installation, commissioning, and qualification of new assembly lines and manufacturing equipment.
• Coordinate with Product Development, Quality, Supply Chain, and Production teams during new product industrialization.
• Prepare and maintain manufacturing documentation including PFD, PFMEA, CP, SOPs, and work instructions.
• Conduct process capability studies, line trials, and process validations.
• Drive continuous improvement initiatives focused on safety, quality, cost, delivery, and productivity.
• Support APQP activities and ensure compliance with customer and industry requirements.
• Troubleshoot manufacturing issues during prototype, pilot, and mass production phases.

Skills

Process engineering

Lean manufacturing

Process validation

Line design

Automation

Education

Bachelor's Degree in Mechanical Engineering

Master's degree (added advantage)

Tools

Hot Plate Welding

Vibration Welding

Ultrasonic Welding

Laser Welding

Robotic gluing programming

PFMEA

APQP

Control Plan

SOPs

MS Office

Job description

Job Title : Sr. Engineer NPD - ME

To support New Product Development (NPD) initiatives by developing, industrializing, and optimizing manufacturing processes for lighting products. The role is responsible for defining assembly processes, establishing production lines, implementing welding and gluing technologies, and ensuring robust manufacturing documentation to achieve quality, productivity, and cost targets.

Key Responsibilities

• Lead manufacturing engineering activities for new lighting product introductions and localization projects.
• Define and develop manufacturing processes for lighting assemblies and sub-assemblies.
• Drive implementation and validation of various welding technologies, including:
  • Hot Plate Welding
  • Vibration Welding
  • Ultrasonic Welding
  • Laser Welding
• Develop, program, and optimize robotic gluing applications to ensure process consistency and quality.
• Prepare assembly line specifications including equipment requirements, cycle time calculations,layout concepts, tooling, and automation requirements.
• Lead installation, commissioning, and qualification of new assembly lines and manufacturing equipment.
• Coordinate with Product Development, Quality, Supply Chain, and Production teams during new product industrialization.
• Prepare and maintain manufacturing documentation, including:
  • Process Flow Diagram (PFD)
  • Process Failure Mode & Effects Analysis (PFMEA)
  • Control Plan (CP)
  • Standard Operating Procedures (SOPs)
  • Work Instructions and Station Documents
• Conduct process capability studies, line trials, and process validations.
• Drive continuous improvement initiatives focused on safety, quality, cost, delivery, and productivity.
• Support APQP activities and ensure compliance with customer and industry requirements.
• Troubleshoot manufacturing issues during prototype, pilot, and mass production phases.

Educational Qualifications

• Bachelor's Degree in Mechanical Engineering, Production Engineering, Industrial Engineering, Mechatronics, or related discipline.
• Master's degree is an added advantage.

Experience

• 7-12 years of experience in Manufacturing Engineering/NPD Engineering within the Automotive, Lighting, Electronics, or related manufacturing industry.
• Hands-on experience in assembly process development and production line setup.
• Proven experience in industrializing new products from concept to mass production.

Required Technical Skills

• Expertise in welding technologies (Hot Plate, Vibration, Ultrasonic, and Laser Welding).
• Experience in robotic gluing programming and process optimization.
• Strong understanding of assembly line design and specification development.
• Experience in new assembly line installation and commissioning.
• Knowledge of APQP, PFMEA, Control Plan, and manufacturing documentation.
• Understanding of automation, poka-yoke systems, and lean manufacturing concepts.
• Familiarity with process validation and capability studies.
• Proficiency in MS Office and engineering documentation tools.