Process Development Manager – Machine Shop Division

Products: Valve Components & Defence Components

Position Details

Particular

Details

Designation

Process Development Manager

Department

Process Development / Machine Shop

Division

Machine Shop Division

Product Category

Valve Components & Defence Components

Reports To

Director

Location

Machine Shop

Experience

10–15 years in CNC machining / process development

Qualification

Diploma / B.E. / B.Tech – Mechanical / Production / Manufacturing Engineering

A. Process Development

- Study customer drawings, specifications, standards and technical requirements.
- Develop complete manufacturing processes for new and existing components.
- Prepare Process Flow Charts, Operation Sheets, Route Cards and Work Instructions.
- Define machining sequence, operation methodology and process parameters.
- Select suitable machines, cutting tools, fixtures, gauges and inspection methods.
- Develop processes for CNC Turning, VMC/HMC, drilling, milling, grinding and other machining operations.
- Identify critical dimensions, special characteristics and key process parameters.
- Establish standard cycle times and process capacity.

B. New Product Development

- Review recent component drawings and assess manufacturability.
- Participate in New Product Introduction (NPI) activities.
- Conduct process feasibility studies before production.
- Develop prototypes / first-off components and coordinate trials.
- Analyse trial results and implement necessary process modifications.
- Support APQP / PPAP activities wherever applicable.
- Ensure proper transfer of new products from development to production.

C. Valve Component Manufacturing

- Develop machining processes for valve bodies, bonnets, stems, seats, discs and other valve-related components.
- Establish machining sequences for critical sealing, threading, boring and dimensional features.
- Improve process capability for critical valve dimensions and functional requirements.
- Coordinate with Quality for inspection and testing requirements.




- Ensure process controls are established for critical characteristics.

D. Defence Component Manufacturing

- Develop controlled machining processes for defence-related precision components.
- Ensure strict adherence to customer drawings, specifications and approved processes.
- Maintain traceability and controlled process documentation.
- Ensure special process and inspection requirements are incorporated into manufacturing documentation.
- Maintain confidentiality of customer/product information and technical documentation.
- Support production of close-tolerance and high-precision components.

E. CNC Programming & Tooling

- Review and develop CNC programs for machining operations.
- Optimise cutting parameters, tool selection and machining strategies.
- Reduce tool consumption and machining time.
- Develop suitable fixtures and tooling in coordination with Tool Room / Production.
- Verify CNC programs before release for production.
- Implement tool-life monitoring and standardisation.

F. Productivity & Cost Improvement

- Analyse machining cycle times and identify improvement opportunities.
- Reduce setup time, tool cost, rejection, rework and machine idle time.
- Implement Kaizen, 5S, Lean Manufacturing and Continuous Improvement activities.
- Improve machine utilisation and overall equipment effectiveness.
- Conduct productivity improvement projects.
- Establish and monitor standard operating times.

G. Quality & Process Control

- Work closely with Quality Assurance to prevent process-related defects.
- Analyse rejection, rework and customer complaints related to manufacturing processes.
- Conduct Root Cause Analysis, 5 Why.
- Implement corrective and preventive actions.




- Support PFMEA and Control Plan preparation and review.
- Identify process risks and establish appropriate controls.
- Monitor process capability (Cp/Cpk) for critical characteristics where applicable.

H. Cross-Functional Coordination

Coordinate with

- Production
- Quality Assurance
- Tool Room
- Maintenance
- Purchase
- Stores
- Planning
- Design / Engineering
- Management

to ensure smooth implementation and control of manufacturing processes. Documentation & ISO 9001:2015

- Ensure process development documents are prepared, reviewed, approved and controlled.
- Maintain Process Flow, PFMEA, Control Plan, Work Instructions and other relevant records.
- Ensure compliance with the organization's ISO 9001:2015 Quality Management System.
- Support internal and external audits.
- Ensure changes to processes are properly evaluated, approved and documented.
- Maintain revision control of process documents.

Authority

- Recommend and establish manufacturing processes.
- Recommend machines, tools, fixtures and gauges.
- Approve process trials within the defined authorization level.
- Recommend process modifications and productivity improvements.
- Stop or hold a process when significant technical or quality issues are identified.
- Recommend corrective actions for recurring process-related problems.
- Recommend investment in new machinery, tooling and technology.

Key Performance Indicators (KPIs)

- New product development completion on time
- Process development lead time
- Reduction in machining cycle time
- Reduction in rejection and rework
- Process capability (Cp/Cpk)
- Tool cost reduction
- Productivity improvement
- Machine utilisation / OEE improvement
- Successful first-off / trial approval
- Customer complaint reduction
- Cost reduction through process improvement
- Timely completion of engineering documentation
- Number of successful

Conduct : (phone hidden) Pay: ₹60,000.00 - ₹70,000.00 per month

Benefits

- Food provided
- Paid time off
- Provident Fund

Work Location: In person

📌 Process Development Manager (Kaniyur)
🏢 Sri Maalathi Engineering Industirees
📍 Kaniyur