Senior Industrial Engineer — Lean Manufacturing & NPI

KPIT

Indianapolis (IN)

On-site

USD 90,000 - 120,000

Full time

14 days+

Application generator

Turn this role into an interview — a resume and cover letter built around what this employer wants.

Get past ATS filters

Job summary

KPIT is seeking an experienced Industrial/Manufacturing Engineer to drive industrialization, planning, and optimization for complex assembly lines. You will work with automated equipment, robotics, and vision systems to improve productivity, quality, safety, and cost efficiency while supporting new product introductions and change management.

The role requires developing standard times, line balancing, PFMEA, and control plans, with a focus on Workforce planning and ergonomic analyses.

Qualifications

Bachelor's Degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, Supply Chain Engineering, or a related discipline.
Master's Degree (MS/M.Tech) in a relevant engineering field is preferred.
Minimum 5- 8 years of experience in Industrial Engineering, Manufacturing Engineering, Process Engineering, or related manufacturing environments.
Experience supporting high-volume assembly operations and automated manufacturing systems.
Proven experience in manufacturing process development, industrialization, and continuous improvement initiatives.

Responsibilities

Establish standard times, manpower projections, line balancing, and standard work element sheets for manufacturing operations.
Conduct work measurement studies and classify activities as Value Added (VA) and Non-Value Added (NVA).
Develop, optimize, and improve workstations in accordance with PFMEA recommendations, Control Plans, and process improvement initiatives.
Create detailed workstation layouts, assembly cell layouts, and manufacturing line layouts.
Define and document manufacturing processes for new, modified, or relocated production lines.
Perform line balancing and determine workforce allocation requirements following process changes and modifications.
Conduct 3M (Muda, Muri, Mura) analysis and ergonomic assessments using Yamazumi Charts.
Identify and implement productivity, quality, safety, and cost improvement opportunities within manufacturing operations.
Develop training materials and work instructions related to process, product, equipment, and manufacturing changes.
Evaluate tooling, fixture, gauge, and equipment requirements and provide recommendations for manufacturing improvements.
Manage Engineering Change Orders (ECOs) and Manufacturing Change Orders (MCOs), including assessment of impacts on standard times and production processes.
Analyze existing manufacturing processes and implement corrective and preventive actions to enhance operational efficiency.
Develop detailed layouts for equipment, workflow, assembly methods, and workforce utilization.
Lead continuous improvement and cost reduction projects using Lean Manufacturing methodologies.
Support New Product Introduction (NPI) activities by developing manufacturing plans, operator work content, machine capability requirements, and quality verification processes.
Lead capacity planning and capital expenditure forecasting activities.
Ensure manufacturing processes comply with safety, quality, and regulatory requirements.
Maintain and update manufacturing documentation, including FMEAs, Control Plans, Work Instructions, Tool Sheets, and Job Instructions.
Provide technical support to production across multiple shifts and resolve manufacturing-related issues.
Prepare technical reports, process documentation, and project updates for stakeholders.
Perform other duties as assigned.