Senior Engineer - Tube Production

Job Description:

Job Summary

We are looking for an experienced Senior Engineer – Production with strong hands-on experience in Single Wall (SW) and/or Double Wall (DW) Tube Manufacturing Mill operations in the automotive industry.

The candidate will be responsible for managing and optimizing tube manufacturing processes, ensuring production efficiency, product quality, minimum rejection, and equipment reliability. The role requires technical expertise in tube forming, sizing, roll pass design, HF/ERW welding processes, and shop floor management.

Key Responsibilities

• Plan, manage, and monitor daily tube manufacturing activities to achieve production targets.

• Oversee tube forming, welding, sizing, cutting, and finishing operations for Single Wall and Double Wall Tube Mills.

• Handle tube mill setup, commissioning, roll pass design, roll tooling design, and alignment.

• Monitor and optimize production parameters such as mill speed, yield, productivity, and downtime.

• Troubleshoot production issues related to weld defects, sizing problems, surface defects, and process abnormalities.

• Ensure consistent product quality as per customer specifications and industry standards.

• Drive continuous improvement initiatives using Lean Manufacturing, Kaizen, TPM, 5S, and Six Sigma.

• Reduce production losses, rejection, scrap, and machine downtime.

• Coordinate with maintenance teams for preventive maintenance and breakdown management.

• Develop and implement SOPs for mill operations and process control.

• Supervise shop floor operators and technicians, ensuring effective manpower utilization and productivity.

• Train, guide, and mentor operators and production staff.

• Handle overall production activities across shifts and ensure smooth workflow.

• Coordinate with Quality, Maintenance, and Engineering teams to resolve operational issues.

• Ensure compliance with safety and environmental standards.

• Maintain production, downtime, and quality records and prepare MIS reports using ERP and Excel.

• Handle customer quality concerns and support corrective and preventive actions using CAPA, 8D, and 7 QC tools.

Technical Skills Required

• Strong experience in Automotive Tube Manufacturing / Metal Forming Industry.

• Hands-on experience in Single Wall and/or Double Wall Tube Mill operations.

• Strong knowledge of tube forming and sizing processes.

• Knowledge of Roll Pass Design and Roll Tooling.

• Experience in HF / ERW Welding Processes.

• Understanding of material properties and metallurgy.

• Experience in tube mill setup, commissioning, and process optimization.

• Knowledge of Lean Manufacturing, TPM, Kaizen, 5S, and Six Sigma.

• Understanding of IATF 16949:2016 and quality management systems.

• Good knowledge of ERP systems and MS Excel.

• Strong problem-solving, decision-making, communication, and leadership skills.

• Experience in shop floor and manpower management.

Key Performance Indicators (KPIs)

• Production Output and Efficiency.

• Cost Control and Productivity.

• On-Time Delivery (OTD).

• Rejection and Scrap Reduction.

• Equipment Downtime and Reliability.

• Safety Compliance.

• Customer Satisfaction.