Senior Process Manager – Machine shop Full Time NEW

• Collaborate with production & QC teams to align technical capabilities with customer requirements
• Identify, troubleshoot, and resolve process-related issues and Machining defects in a timely manner, implementing corrective and preventive actions (CAPA).
• Align with Foundry shop team & to improve the Casting product quality.
• Scrap Reduction & Quality Improvement
• Conducts root-cause analysis using 8D, Fishbone, FMEA.
• Improves process controls and reduces variations (SPC, CP/CPK improvement).
• Designs fool-proofing solutions to avoid operator/machine errors.
• Process Optimization & Cycle Time Reduction
• Analyses current processes to identify bottlenecks and waste.
• Reduces machine cycle time through method studies, motion analysis, and tooling optimization.
• Implements lean tools such as Kaizen, VSM, SMED, 5S, and Poka‑Yoke.
• Tooling Cost Optimization & Conversion Cost Reduction
• Identifies the opportunities for cost reduction task without impacting quality.
• Improves tool life through innovative solutions.
• Reduces tool changeover time and inventory.
• Layout Improvement & Material Handling Optimization
• Designs efficient shopfloor layouts using Lean layout principles.
• Minimizes material movement and handling losses.
• Ensure ergonomic workstations.
• Identify and implement process improvements to increase production efficiency, reduce scrap rates, minimize waste, and lower costs, optimize the head counts..
• Work closely with cross-functional teams, including quality control, production, maintenance, and R&D, to ensure smooth production flow and the successful integration of new technologies.
• Contribution for New product development & PPAP document preparation.
• Maintain up-to-date documentation of all process procedures, adjustments, and project validation activities, ensuring compliance with safety, environmental requirements.

Your Experience And Qualification

• BE/B. Tech. (Mech/Manufacturing engineering/Material)
• Minimum 10 -15 years’ experience in Machining shop for Casting and Forged components.
• Prefer the knowledge and experience of automotive components, like Camshaft, Crankshaft etc..
• Preference will be given for expertise in CBN Grinding, Turning operation & induction hardening.
• Knowledge of IATF 16949, GD&T, drawings
• Excellent in time-management & team handling abilities.

Minimum Requirements

• Ability to analyze component drawings and prepare machine shop documents (Control plan, process sheet, SOP etc..)
• Ability of Setting and testing optimal cutting speeds, feed rates, and depth of cut to minimize tool wear and production time.
• Proven ability for Researching, selecting, and procuring cutting tools, jigs, fixtures, and CNC equipment to improve production efficiency.
• Understanding of tooling geometry-specification and tool wear mechanisms.
• Proven ability to identify, analyze, and resolve root causes of Machining defects (e.g., roundness, chatter mark, Harmonic, machining crack, Grinding burn marks etc..) using techniques like 8D, Fishbone diagrams, etc…

Our Offering.

We will provide a collaborative environment working on exciting assignments, along with ongoing personal & career development opportunities.

We encourage you to apply even if you don’t meet every single requirement. You may just be the right candidate for this or other roles!

After receiving your online application, the interview process will typically be, once your profile will get shortlisted.

#DiversityMatters with our inclusive culture, we welcome applications from all social, religious & ethnical backgrounds, disabilities both mental and physical, identities (gender) and neurodivergent people.

Do you have any questions?

swati.kshirsagar@MAHLE.COM