TMS Production (Cooling / Coolant Module) - Engineer / Sr. Engineer

Job Description Production Engineer / Senior Production Engineer

A/C System Module HVAC / Cooling & Coolant Module

Company: Leading Korean MNC Company
Location: Sriperumbudur / Chennai, Tamil Nadu
Department: Production / Manufacturing
Position: Production Engineer / Senior Production Engineer
Experience: Minimum 7 years
Industry: Automotive / Automotive Thermal Management

About the Role

We are looking for an experienced Production Engineer / Senior Production Engineer with strong hands-on experience in Automotive A/C System Module, HVAC, Cooling Module or Coolant Module production.

The candidate will be responsible for managing and optimizing the mass-production line, ensuring achievement of production, quality and productivity targets, troubleshooting NG parts, improving manufacturing processes, reducing customer claims and cycle time, and supporting customer audits.

Experience in crimping, clinching, tube/hose assembly, pressure/leak testing and automated assembly processes will be highly preferred.

Key Roles & Responsibilities

1. A/C / HVAC Module Production

• Manage day-to-day production activities for A/C System Module / HVAC / Cooling / Coolant Module production lines.
• Ensure achievement of daily, weekly and monthly production targets.
• Monitor production performance, line efficiency, OEE and productivity.
• Ensure smooth operation of mass-production lines.
• Monitor manpower, machine capacity, material availability and line balance.
• Ensure production is carried out according to approved process standards and work instructions.

2. Manufacturing Process Management

• Set up, operate and optimize production lines for mass production.
• Develop and improve standardized manufacturing processes.
• Monitor cycle time and identify bottlenecks.
• Conduct line balancing and manpower optimization.
• Improve machine utilization and overall equipment effectiveness.
• Support new model/product launch and process implementation.
• Coordinate with Maintenance, Quality, PPC, Engineering and other departments for production continuity.

3. Crimping / Clinching / Assembly Process

• Manage and troubleshoot crimping and clinching processes used in A/C/cooling module assembly.
• Monitor critical process parameters and ensure process stability.
• Handle tube, pipe and hose assembly/joining processes.
• Ensure proper component joining, sealing and dimensional requirements.
• Monitor crimping/clinching tool and fixture conditions.
• Analyze crimping and joining-related defects and implement corrective actions.
• Ensure proper poka-yoke and error-proofing systems are implemented.

4. Leak Testing / Pressure Testing

• Manage leak testing and pressure testing processes for A/C/cooling modules.
• Monitor leak-test parameters and ensure proper test conditions.
• Troubleshoot leakage-related NG parts.
• Identify whether leakage is related to components, joints, seals, O-rings, fixtures or process conditions.
• Monitor pressure/vacuum testing equipment and coordinate calibration/maintenance.
• Implement corrective actions to reduce leakage defects and customer complaints.
• Maintain leak-test records and process documentation.

5. Quality & NG Part Troubleshooting

• Monitor daily quality performance and analyze NG/rejected parts.

• Conduct root-cause analysis using:

• 5 Why

• Fishbone Analysis

• 4M/5M Analysis

• 8D

• CAPA

• Reduce rejection, rework, scrap and customer complaints.

• Work closely with Quality Engineering to resolve process-related issues.

• Implement corrective and preventive actions.

• Ensure compliance with Control Plan, PFMEA, SOP and Work Instructions.

6. Productivity & Continuous Improvement

• Drive continuous improvement activities on the production line.
• Improve cycle time, productivity, OEE and line efficiency.
• Identify and eliminate process losses and bottlenecks.
• Implement Kaizen and cost-reduction initiatives.
• Reduce manpower requirements through process optimization and automation.
• Improve machine uptime and process capability.
• Support Lean Manufacturing and 5S activities.

7. Operator & Team Management

• Manage and guide production operators and line personnel.
• Allocate manpower according to production requirements.
• Provide process training to operators.
• Ensure operators follow standardized work procedures.
• Monitor operator performance and productivity.
• Ensure proper implementation of safety and quality standards.

8. Customer Audit & Documentation

• Prepare the production line for customer audits.

• Maintain production and process documentation.

• Ensure availability and compliance of:

• SOP

• Work Instructions

• Control Plan

• PFMEA

• Process flow

• Inspection standards

• Production records

• Quality records

• Support customer complaint investigations and corrective actions.

• Participate in internal, customer and system audits.

Required Technical Skills

Must Have

Automotive HVAC / A/C Module Production
Cooling / Coolant Module Production
Mass Production Line Management
Crimping / Clinching
Leak Testing / Pressure Testing
Tube / Hose Assembly
NG Part Troubleshooting
Cycle Time Improvement
OEE / Productivity Improvement
Continuous Improvement / Kaizen

Quality Knowledge

• PFMEA
• Control Plan
• SOP / Work Instructions
• 7 QC Tools
• 5 Why
• Fishbone Analysis
• 8D
• CAPA
• SPC
• MSA
• PPAP
• Poka-Yoke
• Root Cause Analysis

Equipment / Process Knowledge

• Automated assembly lines
• SPM
• Pneumatic systems
• Sensors
• PLC basics
• Press-fit equipment
• Crimping machines
• Clinching equipment
• Leak-test machines
• Pressure/vacuum testing
• Jigs & fixtures
• Torque-controlled tools

Key Performance Indicators KPI

The candidate should be capable of managing:

• Production achievement %
• OEE
• Productivity
• Cycle time
• Line efficiency
• Rejection %
• Rework %
• Scrap %
• Customer complaints
• Customer claims
• Machine downtime
• Changeover time
• Manpower productivity
• Process capability
• Kaizen implementation
• Cost reduction

Qualification

• Bachelor's Degree in Engineering preferably Mechanical / Automobile / Mechatronics / Production / Manufacturing Engineering.

• Minimum 7 years of relevant experience in:

• Automotive A/C Module Production

• HVAC Module Production

• Cooling Module Production

• Coolant Module Production

• Automotive Thermal Management Production

Preferred Experience

Candidates with hands-on experience in:

A/C Module + HVAC + Crimping + Clinching + Leak Testing + Mass Production

will be strongly preferred.