Manager - Process Engineering

Job Summary

Together, we move the world we've been doing it for over 100 years. At MAHLE, as a leading international development partner and systems supplier to the automotive industry, we pursue the objective of making mobility more efficient, more environmentally friendly, more convenient, and more economical. As part of our dual strategy, we are working both on the intelligent combustion engine for the use of hydrogen and other nonfossil fuels and on technologies for fuel cells and e-mobility.

MAHLE generated sales of 11.3 billion. Employing just under 65,000 people at 127 production locations and 11 technology centers, the company is represented in 28 countries.

Your Contribution

• Collaborate with production QC teams to align technical capabilities with customer requirements
• Identify, troubleshoot, and resolve process-related issues and Machining defects in a timely manner, implementing corrective and preventive actions CAPA.
• Align with Foundry shop team to improve the Casting product quality.
• Scrap Reduction Quality Improvement
• Conducts root-cause analysis using 8D, Fishbone, FMEA.
• Improves process controls and reduces variations (SPC, CP/CPK improvement).
• Designs fool-proofing solutions to avoid operator/machine errors.
• Process Optimization Cycle Time Reduction
• Analyses current processes to identify bottlenecks and waste.
• Reduces machine cycle time through method studies, motion analysis, and tooling optimization.
• Implements lean tools such as Kaizen, VSM, SMED, 5S, and Poka Yoke.
• Tooling Cost Optimization Conversion Cost Reduction
• Identifies the opportunities for cost reduction without impacting quality.
• Improves tool life through innovative solutions.
• Reduces tool changeover time and inventory.
• Layout Improvement Material Handling Optimization
• Designs efficient shopfloor layouts using Lean layout principles.
• Minimizes material movement and handling losses.
• Ensure ergonomic workstations.
• Identify and implement process improvements to increase production efficiency, reduce scrap rates, minimize waste, and lower costs, optimize the head counts.
• Work closely with cross-functional teams, including quality control, production, maintenance, and RD, to ensure smooth production flow and the successful integration of new technologies.
• Contribution for new product development and PPAP document preparation.
• Maintain up-to-date documentation of all process procedures, adjustments, and project validation activities, ensuring compliance with safety and environmental requirements.

Your Experience and Qualification

• BE/B. Tech. (Mech/Manufacturing engineering/Material)
• Minimum 10-15 years experience in Machining shop for Casting and Forged components.
• Prefer the knowledge and experience of automotive components, like Camshaft, Crankshaft etc
• Preference will be given for expertise in CBN Grinding, Turning operation induction hardening.
• Knowledge of IATF 16949, GDT, drawings
• Excellent in time-management team handling abilities.

Minimum Requirements

• Ability to analyze component drawings and prepare machine shop documents (Control plan, process sheet, SOP etc)
• Ability of Setting and testing optimal cutting speeds, feed rates, and depth of cut to minimize tool wear and production time.
• Proven ability for Researching, selecting, and procuring cutting tools, jigs, fixtures, and CNC equipment to improve production efficiency.
• Understanding of tooling geometry-specification and tool wear mechanisms.
• Proven ability to identify, analyze, and resolve root causes of Machining defects (eg, roundness, chatter marks, harmonic, machining crack, grinding burn marks) using techniques like 8D, Fishbone diagrams, etc

Job Details

• Entry level: Experienced hires
• Part- / Full-time: Full Time
• Functional area: Product Management
• Department: BU1 Powertrain and Charging
• Location: Pithampur, IN
• Company: MAHLE Engine Comp. (IN)

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