Junior Engineer - Tube Production

Job Description:

Job Summary

The Junior Engineer – Production will be responsible for handling and monitoring Single Wall (SW) and Double Wall (DW) Tube Manufacturing Mill operations, ensuring consistent product quality, production efficiency, and adherence to safety standards.

The role involves monitoring tube mill parameters, supporting process optimization, minimizing production defects and downtime, and coordinating with maintenance and quality teams to achieve production targets. The candidate should have hands-on experience in tube forming, sizing, welding processes, and shop floor production activities in an automotive manufacturing environment.

Plant Operations / Technical Knowledge

• Strong knowledge of tube forming and sizing processes.

• Understanding of Single Wall and/or Double Wall Tube Mill operations.

• Knowledge of Roll Pass Design and Roll Tooling.

• Knowledge of welding techniques (HF / ERW).

• Understanding of material properties and metallurgy.

• Exposure to tube mill setup, alignment, and commissioning.

• Strong analytical and problem-solving skills.

Key Responsibilities

• Monitor and execute daily tube manufacturing activities to achieve production targets.

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

• Monitor production parameters such as mill speed, productivity, yield, and process performance.

• Support mill setup, roll changing, roll alignment, and process adjustments.

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

• Monitor production output, OEE, rejection rates, and downtime.

• Identify opportunities to reduce scrap, rejection, material wastage, and machine downtime.

• Support continuous improvement activities using Lean Manufacturing, Kaizen, TPS, 5S, and DWM practices.

• Ensure tubes meet customer specifications, quality standards, and IATF 16949:2016 requirements.

• Coordinate with the Quality team for inspections, testing, and resolution of quality issues using CAPA, 8D, and 7 QC tools.

• Monitor machine performance and coordinate with the Maintenance team for preventive maintenance and breakdown handling.

• Ensure proper utilization of manpower, machines, and materials on the shop floor.

• Guide and support operators and technicians in daily production activities.

• Follow SOPs, work instructions, and process control standards.

• Ensure compliance with industrial safety standards and promote safe working practices.

• Maintain production, downtime, rejection, and quality records.

• Prepare daily production reports and MIS using ERP systems and MS Excel.

• Coordinate with Production, Quality, and Maintenance teams to ensure smooth manufacturing operations.

• Support shift-wise production activities and ensure achievement of assigned targets.

Key Performance Indicators (KPIs)

• Production Output and Efficiency.

• OEE and Productivity.

• Rejection / Scrap Rate.

• Machine Downtime.

• Cost and Material Waste Reduction.

• On-Time Delivery (OTD).

• Safety Compliance.

• Customer Satisfaction.

Key Skills Required

• 3–5 years of experience in Automotive Tube Manufacturing / Metal Forming Industry.

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

• Strong understanding of tube mill operations and welding processes (HF / ERW).

• Knowledge of tube forming, sizing, and roll pass design.

• Understanding of production processes and shop floor management.

• Familiarity with Lean Manufacturing, TPM, Six Sigma, Kaizen, and 5S.

• Understanding of ISO / IATF 16949:2016 quality systems.

• Basic computer skills with MS Excel and ERP systems.

• Good problem-solving, analytical, communication, and coordination skills.

• Ability to work in a production shift environment and coordinate with shop floor teams.