JOB DESCRIPTIONProduction Consulting Engineer

Company: Grigford Engineering & Consulting Pvt. Ltd.

Department: Manufacturing Excellence & Industrial Consulting

Designation: Production Consulting Engineer

Reporting To: Project Manager / Lead Manufacturing Consultant

Work Location: Client Manufacturing Sites / Project Locations

Employment Type: Full-Time / Project-Based, depending on business requirements

1. Job Purpose

The Production Consulting Engineer will support manufacturing clients in improving production efficiency, productivity, quality, process reliability, and cost competitiveness. The role involves conducting shop-floor assessments, analysing production data, identifying operational bottlenecks, implementing Lean Manufacturing practices, and supporting continuous improvement initiatives. The engineer will work directly with client production teams to convert operational challenges into measurable improvements in manufacturing performance.
1. Key Responsibilities

A. Production Planning & Performance Monitoring

- Monitor daily production against planned targets and customer requirements.
- Analyse production output, cycle time, takt time, machine utilisation, and manpower productivity.
- Identify production bottlenecks, capacity constraints, and workflow imbalances.
- Support production planning, scheduling, and resource allocation.
- Prepare daily, weekly, and monthly production performance reports.

B. Manufacturing Process Improvement

- Conduct shop-floor studies and manufacturing process assessments.
- Identify opportunities to reduce cycle time, setup time, material handling, and waiting losses.
- Implement Lean Manufacturing, Kaizen, 5S, and waste-reduction initiatives.
- Support line balancing, layout optimisation, and workflow improvement.
- Develop standard operating procedures (SOPs), work instructions, and process control documents.

C. Productivity & Cost Optimisation

- Identify opportunities to improve Overall Equipment Effectiveness (OEE).
- Analyse production losses, scrap, rejection, rework, and downtime.
- Recommend measures to improve machine productivity and manpower utilisation.
- Support cost-reduction projects related to material consumption, energy, tooling, and operational losses.
- Track savings and validate improvements using measurable data.

D. Quality & Process Control

- Work with quality teams to reduce process defects and customer complaints.
- Analyse recurring production problems using Root Cause Analysis (RCA), 5 Why, and Fishbone methods.
- Support corrective and preventive actions (CAPA).
- Ensure adherence to process parameters, control plans, SOPs, and applicable quality standards.
- Promote first-time-right production and process discipline.

E.



Maintenance & Equipment Effectiveness

- Coordinate with maintenance teams to reduce equipment breakdowns and unplanned downtime.
- Analyse recurring machine failures and production interruptions.
- Support preventive maintenance and Total Productive Maintenance (TPM) initiatives.
- Identify opportunities for machine performance improvement and basic automation.
- Recommend equipment upgrades and process-control improvements where justified.

F. Industrial Engineering & Manpower Productivity

- Conduct time studies, motion studies, and work-measurement activities.
- Evaluate manpower deployment and workstation efficiency.
- Recommend ergonomic improvements and standardised work methods.
- Assist with production capacity assessment and resource planning.

G. Automation & Digital Manufacturing

- Identify opportunities for PLC-based process control, sensors, and production monitoring.
- Support implementation of digital production dashboards and KPI tracking.
- Assist in identifying suitable automation opportunities based on productivity, quality, safety, and payback.
- Support data collection for Industry 4.0 and smart manufacturing initiatives.

H. Consulting & Client Coordination

- Conduct manufacturing site assessments and collect operational data.
- Interact with production managers, plant heads, supervisors, operators, and maintenance personnel.
- Prepare technical observations, improvement recommendations, and implementation plans.
- Track action items and report project progress to the consulting lead.
- Deliver professional presentations and maintain client confidentiality.

1. Key Performance Indicators (KPIs)

Performance will be assessed against agreed project baselines and improvement targets.
- Improvement in production output and throughput.
- Reduction in cycle time and production bottlenecks.
- Improvement in OEE and machine utilisation.
- Reduction in rejection, scrap, and rework.
- Reduction in downtime and production losses.
- Improvement in manpower productivity.
- Verified cost savings and return on improvement initiatives.
- Timely completion of assessments, reports, and implementation activities.
- Client satisfaction and successful execution of assigned deliverables.

1. Educational Qualifications

- Diploma or Bachelor's degree in Mechanical, Production, Industrial, Manufacturing, or related Engineering disciplines.




- Candidates with practical shop-floor experience and strong analytical skills will be preferred.
- Additional training in Lean Manufacturing, Six Sigma, TPM, Industrial Engineering, or Quality Management will be an advantage.

1. Experience Requirements

- Entry-level: 0–2 years of relevant manufacturing or industrial engineering experience.
- Experienced: 2–5 years of production, process improvement, industrial engineering, or manufacturing operations experience.
- Experience in steel, sponge iron, fabrication, automotive, foundry, forging, or heavy engineering industries will be preferred.

1. Required Technical Skills

- Production planning and control.
- OEE, cycle time, takt time, and capacity analysis.
- Lean Manufacturing, Kaizen, 5S, and TPM.
- Root Cause Analysis and problem-solving tools.
- Time and motion study.
- Basic quality tools and statistical analysis.
- MS Excel, PowerPoint, and production reporting.
- SOP preparation and process documentation.
- Basic understanding of PLCs, industrial automation, and manufacturing data systems.

1. Behavioural Competencies

- Solid analytical and problem-solving abilities.
- Practical, hands-on approach to shop-floor improvement.
- Effective communication and client-interaction skills.
- Ability to work independently and collaboratively.
- Willingness to travel to client sites and industrial locations.
- Professional conduct, discipline, and confidentiality.
- Results-oriented mindset with a focus on measurable improvements.

1. Deliverables

The Production Consulting Engineer may be required to prepare and maintain:
- Production performance assessment reports.
- Shop-floor observation and bottleneck analysis reports.
- OEE, downtime, and productivity analysis.
- Process improvement and action-tracking plans.
- SOPs, work instructions, and standardised work documents.
- Root cause analysis and corrective action reports.
- Cost-saving and productivity improvement trackers.
- Final project progress and improvement reports.

1. Working Conditions

- Deployment at manufacturing plants, workshops, and industrial facilities.
- Regular interaction with production, maintenance, quality, and management teams.
- Domestic travel and occasional extended site assignments, depending on project requirements.
- Compliance with client EHS requirements, site safety procedures, and professional consulting standards.

1. Career Development

The position offers opportunities to develop into Senior Production Consultant, Manufacturing Pay: ₹15,000.00 - ₹25,000.00 per month

Benefits

- Flexible schedule

Education:
- Bachelor's (Preferred)

Willingness to travel:
- 25% (Preferred)

Work Location: In person

📌 Production Consulting Engineer (Jamshedpur)
🏢 Grigford Engineering and Consulting
📍 Jamshedpur