Process Planning & Improvement Engineer

Process Planning Engineer is responsible for developing, optimizing, and maintaining manufacturing processes for power and distribution transformers. The role bridges engineering, production, quality, procurement, and supply chain teams to ensure efficient production, cost optimization, quality compliance, and on-time delivery. The position focuses on translating design requirements into manufacturing work instructions, routing plans, material requirements, and process improvements while supporting continuous improvement initiatives.

Principal Responsibilities / Accountabilities

• Develop manufacturing process plans, routings, and workflows for transformer production.
• Create and maintain Bills of Materials (BOMs), work instructions, and production documentation.
• Define manufacturing sequences for core, coil, tank fabrication, assembly, drying, testing, and dispatch processes.
• Ensure availability of process documentation before production launch.
• Lead the investigation of customer non-conformance reports and all responses using the 8D Problem Solving methodology.
• Analyze engineering drawings and specifications to establish manufacturing methods.
• Determine machine, tooling, fixture, and manpower requirements.
• Support new product introduction (NPI) and engineering change implementation.
• Optimize manufacturing processes to improve productivity and reduce cycle times.
• Ensure routine, type, and special transformer tests comply with IEC, IEEE, ANSI, IS, or customer-specific standards.
• Participate in Value Stream Mapping (VSM) and waste reduction initiatives.
• Promote digitalization and automation opportunities within manufacturing processes.
• Liaise with design engineering, production, quality, procurement, and supply chain teams.
• Support customer inspections and technical discussions when required.
• Provide technical support to shop-floor teams for process-related issues.

WORK EXPERIENCE

COMPETENCIES & SKILLS

• Knowledge of transformer manufacturing processes (core cutting, winding, assembly, tank fabrication, vacuum drying, testing).
• Production planning and process engineering expertise | BOM and routing management.
• Understanding manufacturing drawings and electrical/mechanical engineering principles.
• Familiarity with ERP/MRP systems (SAP, Oracle, Microsoft Dynamics, etc.).
• Knowledge of Lean Manufacturing, Six Sigma, Kaizen, 5S, and Continuous Improvement methodologies.
• Familiarity with ISO 9001 Quality Management Systems.
• Ability to interpret engineering drawings, technical specifications, and test procedures.

PERSONAL ATTRIBUTES

• Strong analytical and problem-solving skills.
• Excellent communication and technical documentation skills.
• Ability to work in a cross-functional global environment.
• Project planning and execution capability.
• Continuous improvement mindset.

EDUCATION & QUALIFICATIONS

• Bachelor’s degree in electrical engineering, Mechanical Engineering, or related field.
• 10+ years of experience in Quality Engineering, preferably in transformer, electrical equipment, or heavy manufacturing industries.
• Experience in transformer testing, quality systems, and manufacturing process control is preferred.

IT SYSTEMS & SOTWARE SKILLS

• MS Office tools: MS Excel, MS Word, MS PowerPoint, MS Project.
• Software: CAD Tools (NX,CATIA,Creo,Solidworks)  ERP System (SAP), MES(Simatic IT, Solumina)
• Analysis tools: Minitab14 and
• Product Lifecycle Management: Siemens Teamcenter / ptc Windchill / Dassualt Innovia