Senior Production Engineer

Main Scope

The Senior Production Engineer is responsible for overseeing and controlling all aspects of production operations within the Feeder Shop and/or Assembly Sections of SKM. The role ensures the achievement of production plans, quality standards, cost objectives, and delivery targets while continuously improving manufacturing processes, productivity, and operational efficiency through the implementation of lean manufacturing practices and process optimization initiatives.

Main Responsibilities

Production Planning & Operations

• Attend daily production meetings and provide updates on section performance, output, and production status.
• Plan and coordinate daily production activities with Foremen and Charge hands based on production schedules and priority requirements.
• Monitor production performance to ensure adherence to production plans, quality standards, and delivery commitments.
• Review, analyze, and update production interruption reports and implement corrective actions to minimize downtime.
• Identify opportunities to reduce production losses, material wastage, and operational inefficiencies.
• Improve routing times and reduce lost hours as reflected in weekly efficiency reports.
• Ensure effective utilization of manpower, materials, machinery, and production resources.

Process Improvement & Lean Manufacturing

• Implement and sustain Lean Manufacturing tools and methodologies across the shop floor.
• Conduct process reviews and continuous improvement initiatives to enhance productivity, quality, and cost efficiency.
• Analyze production data and recommend process improvements to reduce cycle times and improve workflow efficiency.
• Monitor and evaluate machine and operational performance to drive manufacturing excellence.

Quality Management

• Review deviation reports, Non-Conformance Notices (NCNs), and defect analysis reports.
• Coordinate with production teams to implement corrective and preventive actions.
• Ensure products and assemblies comply with required specifications, engineering standards, and quality requirements.
• Support continuous improvement initiatives aimed at enhancing product quality and reducing defects.

Team Leadership & People Management

• Supervise and guide Foremen, Charge hands, and production personnel to achieve operational objectives.
• Review performance appraisals prepared by section Foremen for production employees.
• Review and approve day and night shift assignments and communicate schedules accordingly.
• Foster teamwork, accountability, and a culture of continuous improvement within the production team.

Feeder Shop Responsibilities (Fabrication, Coil Shop, Model Shop & Tube Shop)

• Prepare and submit weekly machine breakdown and maintenance reports.
• Review and analyze time-study reports for machines and operations to improve productivity and machine utilization.
• Monitor manufacturing processes related to metal components fabrication, tube processing, coil production, brazing, soldering, and welding operations.
• Ensure compliance with production standards and process controls within feeder shop operations.

Assembly Line Responsibilities

• Continuously monitor assembly processes and verify compliance with Bills of Materials (BOM).
• Plan and coordinate product changeovers by ensuring the availability of required materials and sub-assemblies.
• Verify that all sub-assemblies meet engineering specifications and quality requirements prior to assembly.
• Ensure smooth production flow and achievement of assembly output targets.

QHSE & Excellence Standards

• Comply with all Quality, Health, Safety, and Environmental (QHSE) policies, procedures, standards, and guidelines.
• Ensure a safe working environment and promote adherence to safety regulations within the production area.
• Support the achievement of departmental objectives and Key Performance Indicators (KPIs).
• Comply with customer satisfaction standards and requirements, including ISO 10000, ISO 10001, ISO 10002, ISO 10003, and ISO 10004.
• Understand, implement, and promote the SKM QHSE Policy across all operations.
• Contribute to the achievement of company objectives and operational excellence initiatives.
• Perform any other duties assigned by Management in line with business requirements.

Education

• Bachelor's Degree or master's in mechanical engineering, Industrial Engineering, Manufacturing Engineering, or a related discipline from a recognized and reputable institution.

Knowledge Requirements

• Strong knowledge of engineering principles, manufacturing processes, and industrial production techniques.
• Sound understanding of HVAC manufacturing processes, including fabrication, brazing, soldering, welding, and assembly operations.
• Knowledge of machines, tools, equipment operation, maintenance, troubleshooting, and process optimization.
• Familiarity with Lean Manufacturing, Continuous Improvement, and productivity enhancement methodologies.
• Knowledge of production planning, capacity utilization, workflow management, and operational efficiency practices.
• Proficiency in Microsoft Office applications, including Word,…