Senior Engineer Assembly & Packing Process Full Time NEW

Designation: Senior Engineer, Assembly & Packing Process.

Reporting to: Leader, Final Inspection & Packing Process.

Senior Engineer Assembly & Packing Process

Job Responsibilities

• Manage all KPIVs on a daily, weekly, and monthly basis and ensure they are under control by analyzing the reasons for abnormalities and initiating corrective action. Assisting the leader in identifying new KPIVs and KPOVs as required.
• Executes Daily, Weekly, and Monthly Objectives and is responsible for driving the results in Safety, Quality, Delivery & Cost in their respective area.
• Identify and capture all the KYTs and HIRA points to foster a strong safety culture. Provide safety training and ensure the process complies with EHS policies.
• Responsible for taking actions to strengthen 5S & Kaizen culture within their respective area and ensure the actions are sustained in bringing out consistent results.
• Continuously identify opportunities and provide solutions to the challenges through collaboration and structured problem-solving (through Cost Improvement Projects, Daily Management Meetings) to enhance production efficiency and reduce waste.
• Responsible for managing employee relations, shift planning, and performance management to maintain a positive and productive work environment.
• Ensure all associates follow Standard Operating Procedures defined without any deviation from Standard processes by conducting Gemba and Audits. Improve the processes by identifying and reducing waste in the standards through Kaizen.
• Responsible for managing inventory levels across operational supplies and finished products as per the Production Plan.
• Assist the Department Leader in delivering Opex and Capex-related projects & ensure high levels of supply Quality.
• Perform the operation culture requirements by adhering to Leader Standard Work, actively conducting Daily Management Meetings, and driving continuous improvement through Kaizen initiatives within the Process.
• Responsible for ensuring that autonomous maintenance is done as per the schedule. Coordinating with the Maintenance team to maintain equipment through preventive and predictive maintenance (TPM) for uninterrupted, high-quality production.
• Generate or update standard operating procedures, production, and quality-related documents to enhance production operations. Record and analyse non-conformities, initiate corrective/preventive action for compliance with IMS
• Responsible for ensuring the quality and delivery requirements are met by collaborating with the cross-functional departments (through APDCA, Gemba, KPIV & KPOV Review, MRM, etc)
• Responsible for ensuring the timely calibration of measurement equipment to maintain quality standards.
• Oversee the daily operations of the parts assembly and packing lines to meet production schedules and customer demands.
• Ensure all assembled parts and final packaging meet internal quality standards and engineering specifications.
• Standardize material handling to ensure high-finish ceramic, plastic, and chrome-plated parts are protected from scratches, scuffs, or cosmetic damage during the entire assembly & packing process.
• Develop and maintain specialized assembly jigs, pneumatic torque tools, and fixtures that prevent alignment errors during ceramic-to-plastic or plastic-to-plastic or ceramic-to-metal joining.
• Lead technical investigations into assembly failures using 7QC Tool or 5-Why methodologies, collaborating closely with the vendors and QA teams.
• Implement mistake-proofing systems on the assembly & packing line to ensure zero missing components.
• Manage the receipt, inspection, and storage of incoming materials and semi-finished goods.

Strategic Responsibilities

• Identifying future challenges and opportunities in assembly & packing lines and proactively developing solutions.
• Driving Continuous Improvement and Innovation.
• Improving workplace ergonomics to protect workers and increase productivity.
• Defining and executing automation requirements.
• Internal Stakeholders:
• EHS, Procurement, SOIP, Finance, HR, Maintenance, QA, QC, FG warehouse & Logistics.
• External Stakeholders:
• Global counterparts of other Lixil Plants, Standards auditors. Required Skills and Capabilities:
• Production planning.
• Deep understanding of sanitary ware and plumbing products.
• Strong knowledge of modern packaging materials, box strength calculations (Edge Crush Test / Bursting Strength Test), and automated packing machinery.
• Proficiency in 5S, Kaizen, Time-Motion studies, and Excel for data tracking. Familiarity with SAP/ERP systems is highly advantageous.

Academia: – BE/B.Tech/Mechanical, Production, Industrial, or Plastics/Polymer Engineering.

Professional Experience: – 4+ years in a high-volume manufacturing assembly and packaging environment—preferred within sanitary ware, plumbing fixtures, home appliances, or automotive plastics.