Position Summary

The Assembly Process Engineer is responsible for developing, optimizing, and sustaining assembly processes for gearboxes, geared motors, planetary drives, and related products. The role focuses on improving productivity, quality, safety, and cost efficiency while supporting new product introductions and continuous improvement initiatives across assembly operations.

Key Responsibilities

1. Assembly Process Development & Optimization

- Design, develop, and implement efficient assembly processes and work instructions.
- Define assembly sequences, cycle times, manpower requirements, and line balancing activities.
- Drive productivity improvement projects to achieve operational excellence.
- Identify and eliminate bottlenecks to improve throughput and reduce lead time.
- Conduct time studies and establish standard operating procedures (SOPs).

2. New Product Introduction (NPI)

- Support localization and current product launches from the manufacturing engineering perspective.
- Develop assembly process plans, tooling requirements, and process documentation.
- Participate in design reviews and provide manufacturability feedback.
- Coordinate trial builds and validate assembly processes before production release.

3. Quality & Process Improvement

- Conduct root cause analysis for assembly-related quality issues using tools such as 8D, Fishbone Diagram, and 5 Why Analysis.
- Implement corrective and preventive actions to improve First Pass Yield (FPY).
- Drive Poka-Yoke implementation to prevent defects.
- Participate in PFMEA, Control Plan, and Process Validation activities.

4. Tooling & Equipment Management

- Define and implement assembly fixtures, jigs, torque tools, and testing equipment.
- Ensure proper calibration and maintenance of critical assembly tools.




- Evaluate and recommend automation opportunities to improve efficiency and consistency.
- Support equipment installation, commissioning, and qualification activities.

5. Lean Manufacturing & Continuous Improvement

- Lead Kaizen, Lean Manufacturing, and Value Stream Mapping initiatives.
- Drive waste reduction through continuous improvement projects.
- Improve OEE, productivity, and operational efficiency.
- Promote 5S and Visual Management practices across assembly lines.

6. Safety & Compliance

- Ensure compliance with company safety standards and statutory requirements.
- Conduct risk assessments for assembly processes.
- Support EHS initiatives and promote a safe working environment.

7. Cross-Functional Coordination

- Work closely with Production, Quality, Maintenance, Supply Chain, and R&D; teams.
- Coordinate with global manufacturing engineering teams for process standardization and best practices.
- Support customer audits and internal process audits.

Educational Qualification

- Bachelor's Degree in Mechanical Engineering, Production Engineering, Industrial Engineering, or related discipline.

Experience

- 8-12 years of experience in assembly process engineering within gearbox.

Technical Skills

- Assembly line design and optimization.
- Line balancing and cycle time analysis.
- PFMEA, Control Plan, APQP, and PPAP.
- Lean Manufacturing, Kaizen, and Six Sigma methodologies.
- Root Cause Analysis (RCA) and problem-solving tools.
- Pneumatic, hydraulic, and torque-controlled assembly systems.
- SAP and MES systems knowledge preferred.
- AutoCAD/SolidWorks or equivalent CAD software.

Key Competencies

- Strong analytical and problem-solving skills.
- Project management and execution capability.
- Leadership and stakeholder management.
- Effective communication and presentation skills.
- Continuous improvement mindset.
- Team collaboration and mentoring ability.

📌 Assembly Process Engineer (Tamil Nadu)
🏢 Bonfiglioli
📍 Tamil Nadu