Job Purpose:

Technical lead for motor assembly manufacturing processes, driving process design, NPI, quality, productivity, Lean improvement, and process optimization.

Key Responsibilities:

- Design end-to-end process architecture, station sequence, cycle time, line layout, material flow, and manpower planning.
- Lead NPI / new product launches from feasibility through trials, PPAP, SOP, and mass production stabilization.
- Prepare and maintain PFD, PFMEA, Control Plan, SOP, Work Instructions, process parameters, layouts, and Poka-Yoke.
- Lead DFM/DFA, process feasibility, capacity planning, line balancing, tooling and equipment validation.
- Drive OEE improvement, Kaizen, SMED, TPM, VSM, Lean Manufacturing, productivity and cost reduction initiatives.
- Lead RCA, 8D, CAPA, problem-solving and process improvement for quality and production issues.
- Own process validation, MSA/GR&R;, Cpk, PPAP, Run-at-Rate and process capability studies.
- Support automation, vision systems, robotics, sensors, servo systems and Industry 4.0 implementation.




- Lead cross-functional teams involving R&D;, Quality, Production, Maintenance, suppliers and equipment vendors.
- Mentor junior engineers and ensure process documentation, safety and audit compliance.

Required Experience & Skills:

- B.E./ B.Tech in Mechanical / Mechatronics Engineering.
- 814 years in automotive manufacturing, with 5+ years in motor assembly processes preferred.
- Solid expertise in Process Engineering, Manufacturing Engineering and Industrial Engineering.
- Expert knowledge of PFMEA, Control Plan, PFD, PPAP, APQP, MSA, SPC and Quality Tools.
- Advanced knowledge of Lean Manufacturing, Six Sigma, SMED, TPM, Kaizen, Poka-Yoke and VSM.
- Six Sigma Green Belt mandatory; Black Belt preferred.
- Knowledge of AutoCAD, SolidWorks, Minitab/JMP, GD&T; and process simulation tools.
- Strong technical leadership, problem-solving, project management and cross-functional coordination skills.

📌 Senior Process Engineer (Chennai)
🏢 Johnson Electric
📍 Chennai