Assistant Manager - Manufacturing /Process Engineering

We are looking for an experienced Assitant Manager Manufacturing / Process Engineering Manager to lead manufacturing process development, industrial engineering, equipment selection, line design, capacity planning, and process finalisation & improvement for an EV 2-wheeler manufacturing facility.

The candidate should have strong hands-on experience in MOST, Time Study, Work Study, process finalization for assembly, machine/tool/equipment selection, trolley design, ERP development, PFMEA, project planning, TPM-DM pillar, CAPEX, and budget planning.

The role will work closely with Production, Quality, R&D, Supply Chain, Maintenance, Projects, Purchase, and Finance teams to establish robust, cost-effective, and scalable manufacturing processes.

Key Responsibilities

1. Manufacturing & Process Engineering

• Lead process development and finalization for EV 2-wheeler assembly and manufacturing operations.
• Develop and optimize manufacturing processes, process flow, workstations, line layouts, and material flow.
• Conduct process feasibility studies and identify opportunities for productivity, quality, cost, and safety improvements.
• Develop standardized work instructions, process sheets, operation standards, and line balancing documents.
• Ensure manufacturing processes are capable of achieving defined CT, Takt Time, productivity, quality, and capacity requirements.
• Drive continuous improvement in assembly processes through data-based analysis and industrial engineering techniques.

2. MOST / Time Study / Work Study

• Conduct hands-on MOST (Maynard Operation Sequence Technique) studies for manufacturing and assembly operations.
• Perform detailed Time Study and Work Study for operations and manpower planning.
• Establish standard times and manpower requirements for various operations.
• Conduct line balancing based on Takt Time, cycle time, and production volume.
• Identify and eliminate process losses, unnecessary motion, waiting time, bottlenecks, and non-value-added activities.
• Develop productivity improvement plans based on industrial engineering studies.

3. Machine, Tool & Equipment Selection

• Lead the selection of machines, tools, fixtures, jigs, and manufacturing equipment for new and existing processes.
• Prepare technical specifications and URS for manufacturing equipment.
• Evaluate suppliers and conduct technical discussions for equipment finalization.
• Ensure equipment selection is aligned with process capability, capacity, quality, ergonomics, safety, and CAPEX budgets.
• Support equipment FAT, installation, commissioning, trials, and process validation.

4. Assembly Line & Process Finalization

• Design and finalize EV 2-wheeler assembly lines and associated processes.
• Develop station-wise process layouts and define manpower, equipment, tools, fixtures, and material requirements.
• Optimize workstation ergonomics and operator movement.
• Drive line balancing and capacity optimization.
• Establish processes for critical EV assembly operations while ensuring quality and process consistency.
• Coordinate with Quality and Production teams for process validation and final sign-off.

5. Trolley / Material Handling Design

• Lead the design and development of material handling trolleys, bins, racks, fixtures, and shop-floor handling systems.
• Define trolley specifications based on component dimensions, weight, ergonomics, line-side storage, and material-flow requirements.
• Work with vendors/internal design teams for trolley development, trials, and finalization.
• Ensure material-handling solutions minimize damage, movement, space utilization, and operator effort.

6. PFMEA & Process Quality

• Lead or support preparation and review of Process FMEA (PFMEA) for manufacturing and assembly processes.
• Identify potential process failure modes and implement preventive/detection controls.
• Work closely with Quality Engineering to establish process controls and reaction plans.
• Ensure PFMEA findings are incorporated into process design, equipment specifications, and control plans.
• Drive closure of process-related risks identified during trials and production ramp-up.

7. ERP / Manufacturing System Development

• Participate in ERP development and implementation from a manufacturing/process engineering perspective.
• Define manufacturing process structures, routing, BOM requirements, operation sequences, cycle times, and related master data.
• Coordinate with IT/ERP teams for system configuration and process integration.
• Ensure ERP processes accurately reflect shop-floor manufacturing operations.
• Identify opportunities for digitalization and improved manufacturing data visibility.

8. Project Planning & New Product / Plant Projects

• Develop and manage detailed project plans and project timelines for manufacturing engineering activities.
• Plan activities covering process development, equipment selection, procurement, installation, commissioning, trials, validation, and SOP readiness.
• Track project milestones, risks, dependencies, and action plans.
• Coordinate with cross-functional teams and equipment suppliers to ensure timely project completion.
• Support new model introduction, line expansion, capacity enhancement, and new plant/project activities.

9. TPM DM Pillar

• Drive implementation of TPM – Development Management (DM) Pillar activities within Manufacturing/Process Engineering.
• Support equipment and process improvement initiatives aimed at improving reliability, productivity, quality, and maintainability.
• Drive structured problem-solving and loss analysis.
• Support TPM maturity improvement through standardization, data analysis, and cross-functional improvement projects.

10. CAPEX & Budget Planning

• Prepare annual and project-specific CAPEX requirements for manufacturing equipment, tools, fixtures, automation, material handling, and process improvements.
• Develop technical justification and cost estimates for CAPEX proposals.
• Manage project budgets and monitor actual expenditure against approved budgets.
• Work with Purchase, Finance, and suppliers to achieve cost-effective solutions.

Identify opportunities for CAPEX optimization without compromising safety, quality, capacity, or process capability.

11. Continuous Improvement

• Drive Kaizen, productivity improvement, cost reduction, line balancing, and process optimization initiatives.
• Identify and eliminate manufacturing losses and bottlenecks.
• Improve manpower productivity and equipment utilization.
• Develop and track process engineering KPIs.
• Benchmark manufacturing practices and implement best practices across production lines.

Key Skills Required

• MOST / Time Study / Work Study
• Industrial Engineering and Line Balancing
• Manufacturing Process Development
• EV 2-Wheeler Assembly Process Engineering
• Machine, Tool & Equipment Selection
• Jigs, Fixtures & Trolley Design
• PFMEA
• Process Flow & Standardized Work
• Takt Time / Cycle Time Analysis
• Capacity & Manpower Planning
• ERP / Manufacturing ERP Development
• Project Planning & Execution
• TPM – DM Pillar
• CAPEX Planning & Management
• Budget Planning
• Kaizen / Continuous Improvement
• Supplier Technical Evaluation
• New Line / New Model Introduction
• Cross-functional Project Management

Candidate Profile

• 06–12 years of relevant experience in Manufacturing Engineering / Process Engineering / Industrial Engineering.
• Experience in EV 2-wheeler, automotive, automobile, or high-volume assembly manufacturing is highly preferred.
• B.Tech / B.E. Mechanical Engineering from an A-grade/reputed engineering college.
• Strong hands-on experience in MOST, Time Study, Work Study, and line balancing.
• Proven experience in machine/tool/equipment selection and process finalization.
• Experience in assembly line development and process industrialization.
• Strong understanding of PFMEA and manufacturing process controls.
• Experience in CAPEX, budget planning, project planning, and equipment procurement.
• Experience in ERP development / implementation from a manufacturing perspective.
• Strong exposure to TPM and DM Pillar activities.
• Excellent analytical, project management, vendor management, and cross-functional coordination skills.
• Strong understanding of manufacturing cost, productivity, quality, safety, ergonomics, and process optimization.

Key Performance Indicators (KPIs)

• Line productivity and manpower efficiency
• Achievement of Takt Time / Cycle Time
• Line balancing efficiency
• Manufacturing process readiness for SOP
• New project milestone adherence
• CAPEX adherence and cost optimization
• Process improvement / Kaizen implementation
• Manufacturing cost reduction
• Process quality and PFMEA closure
• Equipment and process capacity achievement
• Reduction in manufacturing losses and bottlenecks

Work Location : Pune