Incharge - Manufacturing Engineering

Job Description Position: In-Charge - Manufacturing Engineering (Control Panel Unit) Department Manufacturing Engineering Reporting To Production Head / Plant Head Location Coimbatore Job Summary The In-Charge - Manufacturing Engineering will be responsible for developing, implementing, and continuously improving manufacturing processes for the Control Panel Unit of Wind Turbine Generators. The role will focus on process design, workstation engineering, tooling and gauge development, work instructions, productivity improvement, quality enhancement, line balancing, and manufacturing cost optimization. The incumbent will serve as the bridge between Engineering, Production, Quality, Planning, and Maintenance to ensure that all manufacturing activities are executed efficiently, safely, and in accordance with quality standards. Key Responsibilities Manufacturing Process Development Develop and standardize manufacturing processes for Control Panel, Hub Panel, Bottom Panel, and Battery Box assembly operations. Establish manufacturing methods for wire harnessing, crimping, bus bar preparation, copper fabrication, and panel assembly activities. Define standard operating procedures (SOPs), work instructions, and process parameters. Introduce best manufacturing practices to enhance productivity and quality. Production Process Engineering Design and optimize production workflows for: Wire Crimping Operations Wiring Harness Preparation Bus Bar Fabrication Copper Cutting, Bending, Punching & Tapping Sheet Metal Drilling & Tapping Control Panel Assembly Hub Panel Assembly Bottom Panel Assembly Battery Box Assembly Establish process flow charts and manufacturing standards. Ensure smooth integration between sub-assembly and final assembly operations. Workstation & Assembly Line Engineering Design and improve assembly workstations to maximize productivity and ergonomics. Develop detailed assembly station layouts. Optimize material flow and workstation arrangements. Conduct line balancing studies and manpower optimization exercises. Improve operational efficiency by reducing non-value-added activities. Tooling, Fixtures & Gauge Development Design, develop, and implement: Production Fixtures Assembly Jigs Inspection Gauges Testing Fixtures Process Aids Ensure tools and fixtures support consistent quality and productivity. Coordinate with suppliers and toolmakers for fixture and gauge manufacturing. Manufacturing Documentation Prepare and maintain: Process Sheets Standard Operating Procedures Work Instructions Control Plans Inspection Standards Process Flow Diagrams PFMEA Documentation Ensure all manufacturing documentation is updated and controlled. Quality Engineering Support Develop and implement process control plans. Support Quality teams in identifying and eliminating process-related defects. Conduct root cause analysis for assembly, wiring, and fabrication-related issues. Implement corrective and preventive actions to improve product quality. Support first-pass yield and zero-defect initiatives. Productivity & Continuous Improvement Drive Lean Manufacturing initiatives across production lines. Conduct cycle time studies and productivity improvement projects. Improve Overall Equipment Effectiveness (OEE) and line efficiency. Lead Kaizen, PDCA, and cost-reduction initiatives. Reduce rework, rejection, and material wastage. New Product Introduction (NPI) Support introduction of new panel designs and engineering changes. Review product designs for manufacturability and ease of assembly. Participate in Design for Manufacturing (DFM) reviews. Ensure smooth transition from design stage to production stage. Material Flow & Process Optimization Establish efficient material handling and material presentation systems. Coordinate with Planning and Stores departments to optimize material movement. Ensure production-ready kits and line-side material availability. Minimize production delays arising from process inefficiencies. Equipment, Maintenance & Calibration Support Define equipment requirements for manufacturing operations. Support installation and commissioning of new equipment. Ensure production tools, fixtures, gauges, and measuring instruments are calibrated. Coordinate preventive maintenance requirements with the Maintenance department. Recommend automation opportunities wherever feasible. Safety, Environment & 5S Implementation Incorporate safety requirements into manufacturing processes. Ensure all assembly stations comply with safety and ergonomic standards. Drive 5S implementation across the shop floor. Ensure fabrication processes eliminate contamination risks from metal chips and debris entering assembly areas. Support EHS initiatives and regulatory compliance. Training & Skill Development Train production personnel on new processes, equipment, and work instructions. Support competency development and skill matrix preparation. Evaluate operator proficiency and process adherence. Promote multi-skilling and operational flexibility within production teams. Educational Qualification Bachelor's Degree in Mechanical Engineering, Production Engineering, Manufacturing Engineering, Electrical Engineering, Electronics Engineering, or related discipline. Certification in Lean Manufacturing, Six Sigma, Industrial Engineering, or Quality Management will be an added advantage. Experience 6-10 years of experience in Manufacturing Engineering or Production Engineering. Experience in Control Panel Manufacturing, Electrical Equipment Manufacturing, Switchgear, Industrial Automation Panels, Renewable Energy Equipment, or Wind Turbine Generator Manufacturing preferred. Position Specific Skills Manufacturing Engineering Skills Process Design & Development Manufacturing Feasibility Analysis Assembly Line Engineering Line Balancing Industrial Engineering Work Measurement & Time Study Lean Manufacturing Kaizen & PDCA Root Cause Analysis Technical Skills Control Panel Manufacturing Wiring Harness & Crimping Processes Bus Bar Fabrication Copper Bending, Punching & Tapping Sheet Metal Operations Fixture & Gauge Design Process Validation Engineering Drawings Interpretation AutoCAD / SolidWorks / Creo SAP / ERP Systems Quality & Process Skills PFMEA Control Plans Process Audits CAPA Quality Improvement Statistical Process Control First Pass Yield Improvement Key Competencies Manufacturing Excellence Analytical Thinking Process Optimization Problem Solving Project Management Cross-Functional Coordination Leadership & Team Development Attention to Detail Continuous Improvement Mindset Decision Making Communication & Presentation Skills