Division BAL Akurdi Department Materials Level / Grade L3 (EX) Functional Area Proprietary 1 Job Title MGR (MATLS QLTY – PROPRIETARY) 2 Reporting Functional reporting to : MANOHAR S SAMAGA 3 Background i) Educational Qualification • Filling a position vacated recently in Materials Proprietary Parts Quality section Desirable: B.E. (Mechanical) , (Production) ii) Experience Minimum: 8 Maximum: 10 iii) Age Limit Minimum: 30 Maximum: 35 4 Job Role & Responsibilities Applicable parts : • Clutch Assembly • Engine Piston Assembly • Engine Valves • Engine Valve Guides, Valve Seats (Sintered & Machined) • Engine Chain Tensioners • Engine Oil Pumps • Exhaust Catalyst • EGR Valve/ Oil Cooler • Petrol Tank Caps • Ignition Lock, Seat Lock • Anti-roll bar • Bearings – Ball, Needle, Bimetal • Window regulators New Models : • Run at rate for parts , NC/Improvement points listing, confirmation of corrective actions - CTQ (Critical To Quality) & CTP (Critical To Process). Confirmation of application of Best Practices/ PRBFM (Process Review Based on Failure Modes). • Checking of DR documents / Product test reports /Control Plans/ Inspection Agreements & PDIRs / Checking of 18 IATF documents. • Follow up of dimensional deviations & actions for regularization of tolerances with R&D after process establishment . • Application of ZDM (Zero Defects Methodology) based on CTQs leading to Engineering Fail-safing of process controls & Inspection controls at Assembly, Subassembly & Child parts based on process capability study. Post productionization: • Planned audits of IPO (Input-Process-Output) / Control Plan of recently developed parts. • Monitoring & reduction of monthly QSR & IHR of vendors. • Confirmation of HD of PRBFM points. • Preparation of Best Practices list in addition to PRBFM points. • Initiation of de-skilling projects. • Actions on ‘Weak Vendors’ EFR/Warranty : • Understand each EFR/spike in FFR. • Study root cause with vendor team & BAL CFT team. • Identify the process robustness improvement points. • Incorporate them into IPO Audits or Process audits to confirm sustenance. Desirable skills • Knowledge of TPM application : JH(Jisu Hozen), PM (Preventive Maintenance), Layered audits, KK (Kobetsu Kaizen), Lean manufacturing, Industrial Engineering. • Good exposure to MS Office tools . • Practical applications of SPC (Process study method, Histogram preparation, evaluation of 6 Sigma, Cp & Cpk), Fall Tree / Ishikawa/ Fish Bone diagrams for analysis, DOE (Design of Experiments), KT analysis (Kepner Trego).