Shift Engineer Diamond Wire Bay & Line Operations

Role & responsibilities

* Ensure safe and reliable operation of diamond wire electroplating bays and assigned production lines during the shift.

* Own bay OEE, production output, availability, performance, and quality for assigned lines.

* Execute the shift production plan and coordinate with Day Superintendent and PPC for priorities.

* Ensure threading and changeover times meet defined standards and drive SMED and loss-time reduction initiatives.

* Monitor process parameters such as current, voltage, speed, tension, and temperature within specified control limits.

* Run production bays as per approved recipes, SOPs, and control plans.

* Respond to process alarms, perform first-level troubleshooting, and escalate issues to Process Engineering / CTS when required.

* Ensure sampling, in-process checks, and coordination with QA/Inline Inspection are completed.

* Maintain SPC charts for key bay parameters and support MSA, GR&R, and control-limit reviews.

* Track Ni, diamond, consumables, and energy consumption at bay level and highlight variances against plan.

* Maintain accurate downtime, loss coding, and production data in MES/LIMS.

* Prepare shift reports covering yield, downtime, near misses, abnormal events, and action closures.

* Ensure strict compliance with HSEF standards, PPE requirements, PTW, and LOTO procedures.

* Conduct shift-wise Gemba rounds and ensure timely closure of HSEF actions.

* Lead and coach team members and contract manpower and conduct toolbox talks and on-the-job training.

* Drive 5S, visual management, standard work, and continuous improvement initiatives.

* Participate in Kaizen, problem-solving workshops, and trials for new products, wires, and DPC variants.

Preferred candidate profile

* B.Tech / B.E. in Chemical, Electrochemical, Mechanical, Metallurgical, Materials, Mechatronics, or Production Engineering.

* 3-6 years of experience in high-speed, continuous process industries such as wire drawing, electroplating, copper/tin wire lines, steel cord, wet benches, or wafering.

* Hands-on experience in running multi-station production lines, preferably in 24x7 operations.

* Experience in diamond wire, tungsten wire, electroplated wire, metal finishing, copper/tin/zinc plating, wafering, or wire-saw operations will be preferred.

* Strong understanding of continuous electroplating/coating lines, line balancing, tension control, and basic electrochemistry.

* Exposure to OEE improvement, loss-tree analysis, SMED/changeover reduction, and tiered daily management.

* Working knowledge of MES, SCADA, and LIMS for production tracking, monitoring, and data entry.

* Knowledge of SPC, 5-Why, Ishikawa, A3, and basic DMAIC problem-solving tools.

* Ability to monitor process parameters and perform first-level troubleshooting.

* Exposure to leading or mentoring shift teams and contract manpower will be preferred.

* Strong understanding of SOP execution, PTW/LOTO, risk assessment, and safe working practices.

* Good communication, leadership, teamwork, and collaboration skills.

* Proficiency in MS Office, particularly Excel, PowerPoint, and Word.

* Willingness to work in rotating shifts.