Senior Process Engineer

About FiunEx: FiunEx is a highly specialized profit improvement operation consulting and Engineering service firm,which has a proven track record in flawless execution of projects in over 25 countries. We have developed a niche in Life Sciences sector driving majority of our revenues.

Through our unique engagement model and its success, we have experienced extremely tremendous growth in a short duration. We now have presence in US, Ireland, India and Thailand. For more details about the company, visit our website at www.fiunex.com.

This opportunity is for a Senior Process Project Engineer supporting transformer manufacturing operations in the USA. The role will focus on manufacturing process improvement, capital projects, equipment implementation, production efficiency and cross-functional project execution.

RESPONSIBILITIES

The role involves developing and improving manufacturing processes to produce high-quality transformers safely, efficiently and cost-effectively, while supporting productivity, quality, delivery and continuous improvement objectives.

• Lead manufacturing and process engineering projects from initiation through completion, delivering agreed scope, cost, schedule, quality and functionality requirements.
• Apply structured project-management practices across project initiation, planning, execution, monitoring, control and close-out.
• Develop project documentation including requirements specifications, project charters, work breakdown structures, capital expenditure requests (CERs), project plans, budgets, schedules and risk registers.
• Coordinate the design, procurement, installation, commissioning and qualification/acceptance of manufacturing equipment, tooling, fixtures and process systems.
• Support process development and optimization across transformer manufacturing operations, including core processing and assembly, winding, coil assembly, insulation, tank fabrication, welding/brazing, drying, impregnation, painting, final assembly and testing, as applicable to the facility.
• Work with Manufacturing, Engineering, Quality, Maintenance, Supply Chain and Operations teams to identify process constraints, improve throughput and reduce scrap, rework, downtime and manufacturing cost.
• Support factory acceptance testing (FAT), site acceptance testing (SAT), equipment commissioning and production readiness activities for new or modified equipment and processes.
• Use Lean Manufacturing and Six Sigma principles to optimize process flow, plant layouts, material movement, line balancing, ergonomics and overall equipment effectiveness.
• Develop and implement standard work, process documentation, work instructions, process flow diagrams, control plans and other manufacturing engineering documentation.
• Use quality and problem-solving tools such as Process Maps, Cause-and-Effect (C&E) analysis, FMEA, Pareto analysis, 5-Why and Design of Experiments (DOE), as appropriate, to address process issues and drive continuous improvement.
• Support New Product Introduction (NPI), engineering changes, product/process transfers and production ramp-up activities.
• Partner with Quality and Operations teams to investigate manufacturing issues and implement effective corrective and preventive actions.
• Ensure appropriate change-control, engineering-change and project documentation is completed and maintained for manufacturing projects.
• Track and report project progress, risks, actions, costs and key performance indicators to Engineering and Operations leadership and other stakeholders.
• Manage multiple projects simultaneously and effectively prioritize resources, timelines and deliverables.
• Work with vendors, contractors and equipment suppliers; review technical proposals, specifications, layouts and equipment documentation and coordinate activities through installation and start-up.
• Supervise and provide technical direction to junior engineers, technicians and subcontractors, ensuring effective communication and timely execution.
• Support plant start-up, production ramp-up, shutdown and major equipment installation activities while minimizing disruption to production.
• Promote safe working practices and comply with plant EHS policies, procedures, PPE requirements and applicable safety standards.
• Support manufacturing quality requirements and applicable industry, customer and company standards relevant to transformer production.
• Provide weekly/monthly operational excellence and project updates, including key metrics, project status, risks, savings and improvement actions.

DESIRED SKILLS AND EXPERIENCE

• Minimum 8 years of relevant and recent experience in process engineering, manufacturing engineering and/or project engineering within an industrial manufacturing environment; experience in transformer manufacturing is highly desirable.
• Bachelor’s degree in Mechanical, Electrical, Industrial, Manufacturing Engineering or a related engineering discipline.
• Strong analytical, technical problem-solving and project-management skills.
• Demonstrated ability to independently manage projects while leading cross-functional teams.
• Hands-on experience with manufacturing processes, equipment implementation, process improvement and production engineering.
• Understanding of transformer manufacturing processes such as core cutting/stacking, winding, coil assembly, insulation, tank fabrication, welding/brazing, drying/impregnation, painting, assembly and electrical/mechanical testing, as applicable.
• Experience with capital equipment projects, equipment installation, commissioning, FAT/SAT and production start-up.
• Strong knowledge of Lean Manufacturing and Six Sigma methodologies and their practical application in a production environment.
• Working knowledge of manufacturing quality tools including PFMEA/FMEA, process mapping, root-cause analysis, control plans, SPC and DOE.
• Experience supporting NPI, product transfers, engineering changes and manufacturing process development.
• Ability to develop and maintain engineering and manufacturing documentation, including process specifications, work instructions, project plans and equipment documentation.
• Strong communication and stakeholder-management skills, with the ability to work effectively with customers, vendors, contractors and cross-functional teams.
• Experience leading or participating in manufacturing audits and continuous-improvement initiatives.
• Technical proficiency with modern manufacturing, automation and process technologies.
• Strong understanding of production planning, capacity improvement, material flow, line balancing and equipment utilization.
• Sound technical engineering approach to project execution, risk management and problem solving.
• Proficiency with Microsoft Office applications, including Excel, Word and PowerPoint; experience with project-planning tools is desirable.

KEY COMPETENCIES

• Project Planning & Execution
• Manufacturing Process Engineering
• Transformer Manufacturing Processes
• Capital Equipment & CAPEX Projects
• Lean Manufacturing & Continuous Improvement
• Root Cause Analysis & Problem Solving
• Cross-Functional Team Leadership
• Vendor & Contractor Management
• Process Documentation & Change Management
• Safety, Quality & Operational Excellence

EDUCATION

Bachelor’s degree in Mechanical, Electrical, Industrial, Manufacturing Engineering or a related engineering discipline. Advanced technical qualifications or Lean/Six Sigma certification are an advantage.