Senior Engineer Production

Job Purpose

The Production Engineer will be responsible for optimizing production processes at the recycling facility, driving improvements in capacity utilization, manpower efficiency, and line balancing. The role focuses on implementing productivity, energy-saving, and cost-optimization initiatives while ensuring strict adherence to safety, quality, environmental, and operational standards.

Key Responsibilities

Production Optimization & Capacity Improvement

• •Analyze current production processes across dismantling, shredding, sorting, and material recovery lines to identify bottlenecks and inefficiencies to improve operational performance.
• •Develop and implement plans to improve overall production capacity and throughput of the recycling lines.
• •Drive continuous improvement initiatives using Lean, Kaizen, and Six Sigma methodologies.
• •Track production KPIs (OEE, yield, downtime, cycle time) and drive corrective actions.

Manpower Utilization & Line Balancing

• •Conduct time and motion studies to determine optimal manpower deployment across workstations.
• •Design and implement line balancing plans to minimize idle time and maximize output per shift.
• •Prepare manpower planning and shift rosters in coordination with HR and shift supervisors.
• •Cross-train workforce and standardize work instructions (SOPs) for flexibility across processes.

Productivity, Energy Saving & Cost Optimization

• •Identify and implement productivity improvement projects with measurable output/cost benefits.
• •Monitor energy consumption of machinery and utilities; identify and execute energy-saving initiatives.
• •Analyze cost drivers in production (power, consumables, manpower, wastage) and drive cost-reduction plans.
• •Prepare ROI/cost-benefit analysis for proposed process or equipment improvements.

Safety, Quality, Environmental & Operational Compliance

• •Ensure all production activities comply with EHS (Environment, Health & Safety) norms and e-waste handling regulations (e.g., E-Waste Management Rules, Pollution Control Board guidelines).
• •Enforce use of PPE and safe operating procedures on the shop floor; conduct safety audits and toolbox talks.
• •Ensure adherence to quality standards for segregated/recovered materials as per customer and regulatory requirements.
• •Maintain documentation for statutory and certification audits (ISO 9001, ISO 14001, ISO 45001, R2/e-Stewards where applicable).
• •Coordinate with maintenance team for preventive maintenance to minimize breakdowns and ensure equipment reliability.

Reporting & Coordination

• •Prepare daily/weekly/monthly production MIS reports for management review.
• •Coordinate with planning, quality, maintenance, warehouse, and HR teams for smooth production flow.
• •Participate in daily production review meetings and drive action closure.

Key Skills & Competencies

• •Strong knowledge of production planning, line balancing, and capacity optimization techniques.
• •Hands-on experience with Lean Manufacturing, Kaizen, 5S, and Six Sigma tools.
• •Working knowledge of EHS and environmental compliance requirements in a manufacturing/recycling setup.
• •Analytical skills to interpret production and cost data for decision-making.
• •Proficiency in MS Excel/production MIS tools; ERP exposure preferred.
• •Strong leadership, team management, and cross-functional coordination skills.

Qualification & Experience

• •B.E./B.Tech in Mechanical
• •6–10 years of experience in production/manufacturing operations
• •Certification in Lean/Six Sigma will be an added advantage.

Key Performance Indicators (KPIs)

• •Production capacity utilization (%) and OEE
• •Manpower productivity (output per man-hour)
• •Energy consumption per unit of output
• •Cost per ton/unit processed
• •Safety incidents / near-miss closure rate
• •Compliance audit scores (quality, safety, environmental)