Job Title: Senior Industrial Engineer (Sr. IE) - Industry 4.0

Job Purpose The Senior Industrial Engineer will drive process optimisation, line balancing, capacity planning and lean practices across our high-volume, vertically integrated bicycle factory, and will lead the factory's move to Industry 4.0. The role defines Standard Minute Values (SMV), designs productive layouts, reduces waste and manpower cost per bike, and builds data-driven, digital ways of running the lines. All work must stay aligned with international customer standards, including Decathlon Process Requirements (DPR) and ISO frameworks.

Key Responsibilities

Line Balancing and Takt Time

Design, run and refine operation bulletins and line balancing across fabrication, surface treatment, wheel assembly and the final conveyor lines.

Remove bottlenecks and maximise line efficiency.

Work Measurement and Standards

Carry out method studies and time studies (MOST or stopwatch) and set accurate SMVs.

Own the operation bulletins, SOPs and layout drawings, with proper version control and change control.

Plant Layout and Ergonomics

Design lean, ergonomic workstations and smooth material flow (kitting and water spider routes).

Reduce material handling time and floor footprint.

Capacity and Manpower Planning

Plan direct and indirect manpower from the monthly production schedule, product mix (single speed, multi speed, road) and target cycle times.

Work out line capacity per model against customer plans, and flag gaps early.

Support the review of overstaffing and manpower cost.

Industry 4.0 and Digital Factory





Lead the Industry 4.0 roadmap for the factory, including the ADMANRI maturity assessment and the 20272030 plan.

Set up real-time capture of output, downtime, OEE and line efficiency, and feed it to factory dashboards.

Link shop-floor data to ERP routing and reporting, and move SOPs and work instructions to digital formats.

Study automation and robotics options (welding, wheel truing, paint, assembly), with cost, benefit and payback.

Run small pilots before scaling, and coordinate with technology vendors.

Use data and simulation to support line balancing and capacity decisions.

Lean and Continuous Improvement

Lead Value Stream Mapping, SMED changeover reduction, 5S and Poka-Yoke projects to reduce non-productive time (NPT).

Cost Reduction (VA/VE)

Drive value engineering to lower direct labour cost and overhead per bike.

NPD Interface

Work with NPD to set SMV, line balance and manpower for new models before launch, so the factory is ready.

Quality and Compliance

Work with Quality and Operations so process parameters comply with customer specifications (BOM, TR, DPR) and internal quality gates.

Team and Training

Train line supervisors and team members on standards, time study and lean tools.





Build a capable industrial engineering team with backup cover.

Key Performance Indicators

Line balancing efficiency (%)

SMV accuracy and target adherence

Direct labour productivity (bikes per man-hour)

Manpower cost per bike, and annual savings (Rs lakh)

NPT reduction

OEE and share of lines with real-time data

Industry 4.0 and automation projects delivered on time, with payback

On-time execution of layout and kaizen projects

Key Skills

Advanced time and motion studies, line balancing, plant layout, VSM and SMED.

OEE, MES basics and shop-floor data systems.

AutoCAD for layouts, advanced MS Excel, and ERP routing modules (SAP, Oracle, Infor).

Power BI or similar dashboards; Python or SQL and plant simulation preferred.

Strong analytical problem solving, leadership and cross-functional communication with supervisors and quality managers.

Developing Standards

Data-driven thinking

Problem solving

Digital and automation mindset

Training and mentoring

Qualifications and Experience

B.E. / B.Tech in Industrial Engineering, Production Engineering or Mechanical Engineering.

8 to 12 years of hands-on industrial engineering experience in high-volume discrete manufacturing, automotive assembly or light engineering plants.

Exposure to Industry 4.0 or smart manufacturing projects is strongly preferred.

Lean / Six Sigma Green Belt, Black Belt or MOST certification is preferred.

Expected Behaviors

Problem solver

Taking responsibility

Ad hoc readiness

Time management

Data positive

Good communication

Confidence

📌 Senior Industrial Engineer (Satara)
🏢 Trinity Cycles
📍 Satara