1. New Product &

- Process Development

- Develop and establish manufacturing processes for new products.

- Review product drawings, specifications and process requirements.

- Conduct process feasibility studies and identify manufacturing constraints.

- Support recent product introduction (NPI) and pilot production.

- Prepare and validate process flow, work instructions and standard operating procedures.

2.

Process

Planning &

- Documentation

- Prepare and maintain Process Flow Diagrams (PFD), PFMEA, Control Plans and SOPs.

- Define process parameters, cycle time, manpower and equipment requirements.

- Develop line layouts and optimize material flow.

- Establish standard work and process control methods.

3. Productivity &

- Process Improvement

- Drive cycle-time reduction, line balancing and productivity improvement.

- Identify bottlenecks and implement corrective actions.

- Improve OEE, machine utilization and manpower productivity.

- Apply Lean Manufacturing, Kaizen, 5S and other continuous-improvement techniques.

- Reduce process losses, rejection, rework and material wastage.

4. Quality &

- Problem Solving

- Analyze process-related quality issues using RCA, 5 Why, Fishbone, 8D and CAPA.

- Work closely with Quality, Production, Maintenance and R&D; teams to resolve process issues.

- Implement mistake-proofing (Poka-Yoke) wherever applicable.

- Monitor process capability and ensure adherence to defined specifications.

- Support customer complaints and corrective/preventive actions related to manufacturing processes.

5.

Production

Support





- Provide technical support to production teams for daily process-related issues.

- Monitor process parameters and ensure compliance with standard operating conditions.

- Support trial runs, process validation and mass-production stabilization.

- Train operators and production personnel on revised processes and work instructions.

6. Tooling, Fixture &

- Equipment

- Coordinate with tooling, maintenance and equipment teams for process requirements.

- Develop specifications for jigs, fixtures, gauges and special-purpose machines.

- Participate in machine commissioning and process validation.

- Identify automation opportunities to improve productivity, quality and safety.

7. Cost &

- Efficiency Improvement

- Identify opportunities for cost reduction and value engineering.

- Optimize manpower, machine utilization, material consumption and cycle time.

- Support VA/VE initiatives and productivity improvement projects.

- Track savings generated through process improvement activities.

8. Safety &

- Compliance

- Ensure processes comply with safety standards and company requirements.

- Identify process-related safety risks and implement corrective measures.

- Support risk assessments and secure operating procedures.

- Ensure compliance with applicable automotive quality systems and internal procedures.

Key Skills

- OEE

- Cycle Time

- Line Balance Efficiency

- Productivity

- Process Rejection / PPM

- Rework &
- Scrap

- Process Capability (Cp/Cpk)

- Kaizen / Cost Reduction

- Downtime

- First Pass Yield (FPY)

- New Product Launch / NPI milestones

- Process Audit Compliance

- Customer Complaint / Quality Closure

📌 Process Engineer (Chennai)
🏢 Lucas-TVS
📍 Chennai