Manufacturing Engineer
Manufacturing & Production · Production & Assembly · Manufacturing Engineering · Process Improvement
In short
Responsible for developing, improving, and maintaining Final Assembly manufacturing processes to achieve safe, efficient, cost-effective, and high-quality vehicle production. The role will drive new model introduction, process industrialization, line balancing, cycle-time improvement, ergonomics, automation, quality improvement, and continuous improvement across the Final Assembly shop.
Responsibilities
- Develop and standardize Final Assembly manufacturing processes.
- Prepare and maintain Process Flow, Standard Operating Procedures (SOPs), Work Instructions, and PFMEA.
- Define optimum assembly sequence, workstation layout, and process methodology.
- Establish cycle time, takt time, and manpower requirements.
- Conduct line balancing and optimize operator utilization.
- Lead manufacturing engineering activities for new vehicles/variants.
- Define process requirements, tooling, fixtures, and equipment.
- Support prototype builds, pilot builds, and pre-production trials.
- Ensure manufacturing readiness before SOP.
- Drive lessons learned from existing models into new builds.
- Develop Final Assembly line layouts considering material flow, operator movement, ergonomics, safety, quality, logistics, and future capacity.
- Conduct capacity calculations and bottleneck analysis.
- Establish cycle-time targets.
- Develop & implement line balancing for volume ramp-up.
- Identify and eliminate bottleneck operations.
- Define specifications for assembly tools, fixtures, and equipment.
- Develop requirements for torque tools, lifting aids, assembly fixtures, conveyor systems, AGVs/AMRs, Poka-yoke devices, testing equipment, vision systems, and error-proofing systems.
- Coordinate with suppliers for design, development, and commissioning.
- Conduct FAT/SAT and equipment acceptance.
- Ensure equipment capability meets production requirements.
- Drive First Time Right / Zero Defect manufacturing.
- Develop and implement Poka-yoke solutions.
- Conduct process audits.
- Support analysis of assembly defects using 4M/5M, 5 Why, Fishbone, DMAIC.
- Implement corrective and preventive actions.
- Ensure critical characteristics and special characteristics are properly controlled.
- Improve traceability of critical assembly operations.
- Define torque requirements and tightening strategies.
- Implement controlled tightening systems for critical joints.
- Monitor torque-related defects and improve process capability.
- Identify opportunities for automation and semi-automation.
- Implement digital manufacturing / Industry 4.0 solutions.
- Develop Andon systems, digital work instructions, traceability systems, torque data integration, production dashboards, automated inspection, and vision-based quality checks.
- Utilize production data for process optimization and predictive improvement.
- Conduct workstation ergonomic assessments.
- Reduce awkward postures, excessive reaching, manual lifting, repetitive movements, and operator walking.
- Implement ergonomic aids and lifting devices.
- Ensure compliance with EHS standards and statutory requirements.
- Participate in safety risk assessments and machine/process safety reviews.
- Lead Kaizen / CI projects to improve efficiency and quality.
- Identify and eliminate Muda, Mura, and Muri.
- Apply Lean Manufacturing, TPM, and Six Sigma methodologies.
- Provide daily manufacturing engineering support to Production.
- Resolve process-related abnormalities and problems.
- Support production during volume ramp-up and new model launch.
- Lead cross-functional problem solving with Production, Quality, Maintenance, and Logistics.
Requirements
- Final Vehicle Assembly Manufacturing experience
- Lean Manufacturing
- Line Balancing
- Takt Time & Capacity Planning
- New Model Introduction
- PFMEA & Control Plan
- Poka-yoke
- Ergonomics
- Assembly Tooling & Fixtures
- Industry 4.0
- Six Sigma / Problem Solving
- Project Management
- Cross-functional Team Management
- 8–12 years in automotive OEM / vehicle assembly manufacturing
- B.E./B.Tech in Mechanical / Automobile / Production / Industrial Engineering
Desired Qualifications
- Experience in automotive OEM Final Assembly, particularly in passenger vehicles, commercial vehicles, trucks or buses.
- Exposure to new model launch, line setup, capacity expansion, automation, process improvement, and production ramp-up.
Benefits
- Opportunity to join Volvo Group.
- Work with sharp and creative teams.
- Contribute to shaping sustainable transport solutions.
- Work with next-gen technologies.
- Opportunity to make a difference on a global scale.
- Culture of care, inclusiveness, and empowerment.
- Occasional Travel
Skills
Lean ManufacturingLine BalancingTakt TimeCapacity PlanningNew Model IntroductionPFMEAControl PlanPoka-yokeErgonomicsAssembly ToolingFixturesIndustry 4.0Six SigmaProblem SolvingProject ManagementCross-functional Team ManagementSOPsWork InstructionsTorque toolsLifting aidsAGVsAMRsVision systems4M5M5 WhyFishboneDMAICTPM
#Manufacturing#Engineering#Automotive#Process Improvement#Lean#Six Sigma#Industry 4.0
About Volvo Group
The Volvo Group is one of the world’s leading manufacturers of trucks, buses, construction equipment and marine and industrial engines. The Group also provides complete solutions for financing and service. The Volvo Group, with its headquarters in Gothenburg, employs about 100,000 people, has production facilities in 18 countries and sells its products in more than 190 markets.\n\n
Company
Volvo GroupJob Posted
2 days ago
Employment Type
Full Time
Work mode
On Site
Experience Level
Senior
Locations
Bangalore, India
Hoskote, India
Qualification
Bachelor
Applicants
Be an early applicant
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