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 Current 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 workplace 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

📌 Test Process Engineer (Hyderabad)
🏢 RGBSI
📍 Hyderabad