Process Engineer

Job Description

COMPANY PROFILE:

ideaForge is the leader in industrial and surveillance UAV manufacturing in India with over 90% market share. The organization was established in 2007 by IIT-Bombay alumni and is based out of Navi Mumbai, Maharashtra. ideaForge co-designed India’s first Surveillance quadrotor UAV, NETRA with the Defence Research & Development Organization (DRDO) and is also responsible for engineering the then world’s lightest Autopilot.

ideaForge develops completely indigenous technology for Unmanned Aerial Systems (UAS). Our organization is the pioneer in the UAS segment in India and has multiple IPs to its credit. Our in-house R&D, design, manufacturing, software, services, and training operations give us the flexibility to customize products for an array of requirements. We are continually innovating and experimenting to transform our aerial platforms to offer greater performance, higher reliability, and autonomy.

At ideaForge, our principle behind everything we design, and build is creating an impact – making the world a better and safer place. With this principle as our cornerstone, we have developed UAVs with unmatched global specifications. With this philosophy, we have consistently helped Indian Defense, Paramilitary & Police forces ensure the safety of our citizens and ultimately save precious lives.

POSITION SUMMARY:

Process Enhancement / Improvement: Responsible for the delivery of Advanced Engineered Solutions to the manufacturing plant by deploying world class process technology (Autonomation) to improve, Optimize & Sustain| Safety | CTQ | Productivity|. Documentation Ensuring the systematic work by deploying WI, SOP’s, and process parameters to sustain the quality of the process & product.

Digital Manufacturing: Exposure in Implementation of Ind 4.0 regarding M2M connectivity using IoT and Integrate with Software to Provide a Digital platform for Manufacturing.

Strategic Planning: Analyze, review & monitor the capacity of the production line with respect to Demand Vs Utilization on half yearly/Annually based on business Plan. Execute capacity ramp up plan considering the equipment, machines, tooling’s, jigs, fixture requirement for assembly line.

Automation & Capex Management: Monitor and reporting monthly/Quarterly/Half yearly to finance regarding overall CAPEX (Budget Vs Actual) as Business target. Look for opportunity in current process to de-bottleneck skill of operator by bringing Automation includes the perspective of SQCDP (safety, Quality, cycle time, development, productivity)

Project Management: Overseeing project activities from conceptualization to execution including finalization of technical specifications, procurement / supply of Process equipment’s, stage inspections, scheduling, progress monitoring, Plant layout and manpower planning.                                                               

ROLE DESCRIPTION & SPECIFC DELIVERABLES

This position will be responsible for performing Process analysis, Process improvements, process sustenance, analysis of quality related issues on assembly cells for all the existing & new products. He will be handling Quad & Switch UAV assembly & sub assembly lines. Typical duties include,

1. Co-ordinate & early involvement with R&D design team on all new product development & share improvements required from existing product.
2. Co-ordinate with R&D sustenance team for improvements required in existing product to improve product reliability, yield improvement, assembly rejection reduction, jig, tools & fixture design & improvement.
3. Smooth productionization of the new products, starting from proto assembly, pilot assembly to production of first 3 batches with 95% yield.
4. Propose & execute Small Automation, Automation & cycle time improvement projects.
5. Assist Manufacturing & Quality engineering to implement new equipment & changes to processes through Training, ECN/ECO implementation process.
6. Implementing Equipment Qualification /Process Qualification, SPC, Poka-Yoke, SOP, Work Instruction, Job Card & Setup approvals, FMEA, implement Quality Systems on assembly cells.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

1) Responsible to Work with Stake holder for understanding the requirement for developing a new equipment |Set-up a New Line |Upgrading of existing line/Equipment’s.

2) Responsible for understanding customer requirement and translate into technical specification by considering the product & Process characteristic, Safety, ergonomics, Poka-yoke, and others etc.,

3) Create and develop concept drawing of making new assembly lines | Special purpose machines | Jigs and fixtures- Tooling | and other Test bench development.

4) Responsible for discussing the concept with stake holders, getting mutual understand and get initial buy for making the proposal.

5) Responsible for implementing Manufacturing Flow Charts, Lean work procedures, Control Plans and FMEAs as prescribed by ISO standards and ABS. (For New Line/Existing line)

6) Responsible for preparing Scope of Supply, sending an enquiry to different supplier to get quotes, make the techno commercial comparison and evaluate in terms of Function, Performance and Cost aspects.

7) Responsible for Raising the Capex by making the budgetary proposal along with justification for Management approval.

8) Responsible for qualification of the tools| equipment or Line |Layout mapping etc.… at both supplier end plant end as well.

9) Responsible for Making documentation such as SOP | WI | Manuals etc.

10) Responsible for providing training to the operator and other stake holders from Manufacturing |Maintenance |Quality.

12) Responsible to Trouble Shooting in Process Equipment & tools by using the Problem-solving techniques using 8D|Six Sigma approach

13) Responsible and ensure to make a report regarding the Performance of the process equipment |Tools | Assembly line etc. in terms of OEE

14) Responsible to hand over and sign off process equipment’s, Tools | Assembly line to concern stake holder for the smooth transition from Projects, R&D to Manufacturing.

15) Experience working in a team environment under time and resource pressures.

16) Responsible in Mapping Ind 4.0 requirement for connecting Machine to Machine using IoT device and Integrate with Equipment

17) Weekly and Monthly report out of Project status

18) Responsible for doing the capex management & installation of production line setups.

19) Preparing the capacity analysis and creating new facilities for production and where-house

FUNCTIONAL COMPETENCIES:

• Ability to conceptualize, design and develop SPM with low-cost automation.
• Ability to conceptualize, design & development of efficient jigs, fixtures preferably with automation as feasible (Preferably Assembly tools | Spot Welding |Laser welding |etc….)
• Thorough understanding of GD&T, Tolerance stack-up, Engineering Material properties, DFM concepts, ergonomics & Poka-yokes while proposing any change in the manufacturing set-up as well as designing new manufacturing lines.
• Hands on experience of Process planning, Execution, Line balancing, Capacity Planning & Production Ramp- by Using Gantt Chart/MS Projects
• Ability to apply engineering and scientific principles and disciplines like Problem Analysis and Root Cause Corrective Action; Statistical Process Control; Design of Experiments; Process Validation, Facilities Layout and Process Design. 
• Ability to work in a collaborative team environment and be responsive to production''s needs. 
• Hands on experience in welding technology like Resistance | Plasma | Laser) in terms of electrode selection, parameter setting and optimization.
• Hands on experience in design of Pneumatic circuits and selecting of Pneumatic products based on the application. etc.
• Exposure on PLC like defining I/P’s and O/P’s and Sequence. Hands on experience in selecting the PLC, developing programming and execute the program with the application. (Added Advantage)
• Exposure in problems solving technique such as by implementing SPC, poka-yoke and other problem-solving tools (e.g. Six sigma)
• Hands on experience on making Part drawings| Assembly drawing| details drawing using software such as AutoCAD|3D Modelling such as Solid works/Creo…. Etc.
• Knowledge and experience working on MS Office and MS Projects.
• Knowledge and Experience working on Ind. 4.0

Software Experience:

1)           3D Modelling software - Creo|Solidworks.

2)           2D Drafting – AutoCAD.

3)           Pneumatic – Design of Pneumatic Circuit in Fluid draw, SMC etc.

4)           Lean Tools- Line Balancing, VSM, SMED and OEE etc.

5)           Six Sigma tools-(Preferred Knowledge on DOE, Anova, Process Capability, Gage R &R)

6)           MS- Projects- Project Management

7)           MS-Office Skills Preferred in Word, Excel and PowerPoint

EDUCATION and/or EXPERIENCE:

Bachelor’s degree in Mechanical/ Production Engineering/Mechatronics/ Electrical / with 5+ years of work experience

Skills