Test Process Engineer

Job Title: Test Process Engineer

Experience: 8-10 Years

Qualification: B.E/B.Tech/ M.Tech (Mechanical / Electronics)

Industry: Automotive Manufacturing Industry

Job Location: Hosur

4. KEY ACCOUNTABILITIES:

Description

• Contributes to define Engine & Transmission test strategies and methodologies in cooperation with Product Engineering and Quality
• Contributes to configure test equipment referring to product architecture, production capacity, process development
• Installation & Commissioning of Test bench with clear understanding of sub system and flow of fuel line, coolant line, exhaust and intake lines.
• Contribute to procure test machinery, equipment and ancillaries, starting from initial Statement of Work (Technical Specifications) up to installation and final acceptance inside the production plant
• Sizing of test machinery, based on input technological data
• Contributes to estimate test machinery and equipment investment
• Define the test equipment features
• Manage the whole machinery procurement process
• Coordinate cross-functional WPI sessions / Simultaneous Engineering sessions / co-design sessions
• Testing solution scenarios identification for manufacturing landscape
• Evaluation of technological solutions for testing purposes
• Evaluation of machinery production capacity and related investment
• Technical specifications realization
• Machinery Procurement process leading and follow up
• Product analysis for process machinery design
• Product Families comparison on SW tools
• Machinery Analysis and general architecture identification
• Machinery SW, Mechanical, Electrical and Fluidic Systems integration
• Mechanical, Fluidic, Electric measurement systems management
• Engine NVH Analysis
• Use of statistical methods for quality assurance
• Test Cycles analysis and basic design
• Operation cycle basic design
• Project leading with suppliers and cross functional references in UPE , Plant, Quality

5. COMMUNICATIONS & WORKING RELATIONSHIPS:

• Support Performance champion/Process KTA and work groups for short- and long-term improvement of the workstation and continuously revised the material flow & process automation levels to support to enhance the in process manufacturing quality.
• Leads and coaches new, or with little experience, resources
• Coordinates testing teams for complex programs test strategies
• Coordinates site installation activities for all testing equipment
• Manages global specification with proposals and guidelines introduction
• Perform Gemba (tour de terrain) in the area under control daily.
• Organize meetings with cross function team members to share & align on all proposal before final implementation
• Work in cross-functional teams: customer, supplier, Manufacturing engineering, Quality Department and others when needed.
• Ensure effective communication with all concerned functions

6. Performance INDICATORS (INDICATIVE):

MANAGEMENT OF KEY METRICS:

• Custodian of Testing related studies of all New Product processes
• Capex Planning for new Test Benches
• Automations Level standards
• Benchmark study solution implementations.
• Poka Yoke Implementations related to Testing processes

DATA ACCURECY:

• Real time update of Testing Cycle times & additional features
• Publishing of required study reports as required
• Manage the proper allocation of resources requirements and budget for the area.

TEAM DEVELOPMENT:

• Coach, train and develop Team Leaders for continuous improvement activities
• Create a good working environment in which everyone is treated with dignity and promote good working relationship, while developing engagement of all Team Members.
• Understand the overall social climate and improve
• Ensure Latest Techniques/tools to evaluate all type of flows

7. QUALIFICATIONS, eXPERIENCE & SKILLS:

QUALIFICATIONS:

• Bachelor / Master Degree on Mechanical (preferred), Electronic Engineering
• Experience of 8-10 years in Engine testing (Leak test, cold test, dyno test) benches in similar project management activities (international preferred)

TECHNICAL SKILLS:

• The activity is based on the following knowledge:

• 100% control and Post Process (4)

• Approval drawings (4)

• B/C analysis (4)

• Bid Technical comparison (4)

• CODEP(4)

• Codesign/Simultaneous Engineering (4)

• Corporate Quality Certification Principles (ISO 9001 - IATF) (4)

• Cost Engineering (4)

• Electrification Fundamental: Basics of Electrotechnical (4)

• Engine Test (4)

• Engine Tests Area (4)

• Engine unit and subsystems characteristics (4)

• FMEA (Process and machine) / O & R (4)

• Leak test (4)

• Machine Run-off (4)

• Operation sheets/ time analysis and breakdown (4)

• Principles of Quality management systems and Quality KPIs (4)

• Process Quality Department Process Knowledge (4)

• Production processes knowledge for Quality perspective (4)

• Project documentation: offers, bid, design of the line, supplier documentation (4)

• Q-Stat (4)

• Siemens Teamcenter SW (advanced) (4)

• Site management (4)

• Specific Regulation for measure: EMS (4)

• Technical Specification (4)

• Autodesk /AutoCAD 2D (3)

• Electrification Fundamental: Architectures (3)

• Explosive environments (EN regulations and norms) (3)

• International machine security regulations (3)

• Manual station design (3)

• OEE / OLE (3)

• Technical drawing (3)

• Major / Advanced Kaizen (4)

• Principles of World Class Technology (4)

• Standard Kaizen (4)

• Suggestion System (4)

• Principles of World Class Manufacturing (3)

BEHAVIORAL SKILLS:

• Excellent communication and negotiation skills.
• Strong leadership and team management capabilities.
• Ability to work collaboratively across departments and with external suppliers.
• Detail-oriented with strong organizational and time management skills
• Good written and verbal communication skills.
• Ability to work in a team environment and collaborate effectively with other engineers.

8. COMPETENCIES, CORE VALUES, BEHAVIOURS: -

Core Competencies:

• Basic Knowledge on Engine Assembly Process and deep expertise in Testing process
• Hands on Experience on Dynamometer Calibration and Troubleshooting of equipment especially on IASYS/ADT make bench
• Knowledge on Periodic maintenance of Test bench
• Cold check working experience on - Troubleshooting and Root cause Analysis
• Wear parts and spare parts management related to testing equipment's
• Experience in Cycle time reduction and down time reduction in Test bench and cold testing to increase productivity/quality/safety
• Testing Report Analysis and consolidation of Reports and share to Management weekly/monthly
• Knowledge on basic PC softwares like Excel, powerpoint, Auto CAD

Core Values:

• Creating effective presentations (4)
• Decision Making (4)
• Delegation (4)
• Cross Cultural Presentations (4)
• Managing Effective presentations (4)
• Negotiation and conflict management (4)
• Planning capacity (4)
• Solution finding (4)
• Stress and Time management (4)
• Team Building (4)
• Team Working (4)
• Meeting Effectiveness (3)
• Smart thinking and creativity (3)

Behavioural Attributes:

• Adaptability & Flexibility
• Strong Organizational Skills
• Conflict Resolution
• Leading by Example
• Resilient & Decisive