Manufacturing Engineering

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Job Purpose
Responsible for developing, improving and maintaining Final Assembly manufacturing processes to achieve safe, efficient, c ost-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.
Key Responsibilities
Manufacturing Process Engineering
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.
New Model Introduction / Industrialization
Lead manufacturing engineering activities for new vehicle / Variants
Define process requirements, tooling, fixtures and equipment.
Prepare SOP readiness plans.
Support prototype builds, pilot builds and pre-production trials.
Ensure manufacturing readiness before SOP.
Drive lessons learned from existing models into new builds.
Line Layout & Capacity Planning
Develop Final Assembly line layouts considering:
Material flow
Operator movement
Ergonomics
Safety
Quality
Logistics
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.
Tooling, Fixtures & Equipment
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
Error-proofing systems
Coordinate with suppliers for design, development and commissioning.
Conduct FAT/SAT and equipment acceptance.
Ensure equipment capability meets production requirements.
Quality & Error Proofing
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.
Torque & Process Control
Define torque requirements and tightening strategies.
Implement controlled tightening systems for critical joints.
Monitor torque-related defects and improve process capability.
Automation & Industry 4.0
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
Vision-based quality checks
Utilize production data for process optimization and predictive improvement.
Ergonomics & Safety
Conduct workstation ergonomic assessments.
Reduce:
Awkward postures
Excessive reaching
Manual lifting
Repetitive movements
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.
Continuous Improvement
Lead Kaizen / CI projects to improve:
Identify and eliminate Muda, Mura and Muri.
Apply Lean Manufacturing, TPM and Six Sigma methodologies.
Production & Ramp-up Support
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, Logistics .
Key Competencies
Final Vehicle Assembly Manufacturing
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
Preferred Experience
Candidates with experience in automotive OEM Final Assembly, particularly in passenger vehicles, commercial vehicles, trucks or buses, with exposure to new model launch, line setup, capacity expansion, automation, process improvement and production ramp-up would be preferred.
Experience
8–12 years in automotive OEM / vehicle assembly manufacturing
Education
B.E./B.Tech in Mechanical / Automobile / Production / Industrial Engineering
Location
Hoskote
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Who We Are And What We Believe In
We are committed to shaping the future landscape of efficient, safe, and sustainable transport solutions. Fulfilling our mission creates countless career opportunities for talents across the group’s leading brands and entities.
Applying to this job offers you the opportunity to join Volvo Group. Every day, you will be working with some of the sharpest and most creative brains in our field to be able to leave our society in better shape for the next generation. We are passionate about what we do, and we thrive on teamwork. We are almost 100,000 people united around the world by a culture of care, inclusiveness, and empowerment.
Trucks Technology & Industrial Division hire team players who are ready to create real customer impact. Our decentralized teams work close to our customers, with speed and autonomy, to build what they truly need.
Join us to collaborate on innovative, sustainable technologies that redefine how we design, build, and deliver value. Bring your curiosity, your expertise, and your collaborative energy, and together, we’ll turn bold ideas into tangible solutions for our customers and contribute to a more sustainable tomorrow.