Senior Engineer - Gravity Die Casting Production

Company Overview

Established in 1982, Sigma Electric Mfg Corporation Pvt. Ltd. specializes in manufacturing assemblies with metal castings and injection molded parts. They offer comprehensive turnkey solutions including product design, tooling, testing, approvals, assembly, and customized packaging for customers across multiple continents. Their manufacturing spans several plants in India producing over 18,000 products primarily aimed at North American markets, with a workforce of approximately 3,000 employees.

Job Summary

This role involves overseeing planning, execution, monitoring, and enhancement of gravity die casting and machine shop production across three shifts, ensuring high standards in safety, quality, delivery, and cost efficiency.

Key Responsibilities

• Manage manpower across all three shifts effectively.
• Monitor and achieve daily production targets aligned with shift plans.
• Ensure operator safety and maintain quality levels (minimizing rejections and PDI issues), optimize Overall Equipment Effectiveness (OEE), and meet delivery timelines.
• Handle fill rates and address customer complaints promptly.
• Work on continuous cost improvement initiatives related to production conversion.
• Implement and sustain plant 5S methodologies and Total Productive Maintenance (TPM) practices.
• Meet monthly budget objectives concerning safety, quality, delivery, cost, 5S, and TPM activities within shifts.
• Address and resolve PDI holds, product rework, customer complaints, and rejection issues.
• Coordinate production activities in collaboration with machine shop and paint shop teams.
• Minimize downtime in pressure die casting processes through effective management.
• Ensure adherence to established processes and systems.
• Enhance die casting shot output per machine and manage fettling outputs while reducing fettling workload.
• Lead efforts to improve and maintain 5S standards in die casting, fettling, melting, and machine shop areas.

Qualifications and Experience

• Diploma in Mechanical Engineering is required.
• At least 5 to 7 years of experience in pressure die casting within a reputed organization is mandatory, with deep knowledge of trimming, melting, and fettling processes.
• Proficient with quality and manufacturing methodologies, including the 7 QC tools, Six Sigma, TPM, 5S, Lean Manufacturing, Kaizen, and SMED.
• Familiarity with ISO and OHSAS standards.
• Skilled in pressure die casting cold chamber machine parameter settings and die loading/unloading.
• Strong understanding of post-foundry and machining operations.

Personal Attributes

• Process-oriented mindset with strong analytical skills.
• Cost-consciousness and a drive for innovation and creativity.
• Initiative taker with leadership and people management capabilities.
• Effective written and verbal communication skills.