Job Requirements
Why work for us?
Alkegen brings together two of the world’s leading specialty materials companies to create one new, innovation-driven leader focused on battery technologies, filtration media, and specialty insulation and sealing materials. Through global reach and breakthrough inventions, we’re delivering products that enable the world to breathe easier, live greener, and go further than ever before.
With over 60 manufacturing facilities with a global workforce of over 9,000 of the industry’s most experienced talent, including insulation and filtration experts, Alkegen is uniquely positioned to help customers impact the environment in meaningful ways.
Alkegen offers a range of dynamic career opportunities with globe-spanning reach. From production operators to engineers, technicians to specialists, sales to leadership, we’re always looking for top talent ready to bring their best. Come grow with us!
Job Requirements:
The Process Engineer supports the manufacturing process from both an operational and technical stand point. Key focus on efficiency, continuous improvement and problem solving; leading and coaching problem solving through root cause analysis. Applicants must possess experience of manufacturing operations and be dynamic and self – motivated.
Process and Quality are areas of key focus for the business and it is therefore the responsibility of the Process Engineer, as with every member of the team, to ensure that all activities are undertaken in a safe and sustainable manner.
The Process Engineer will also be part of key growth projects working with the growth team and the site team to trial new products on site and support with technical development and commercialization.
Work Shift : 9:30AM - 6:30PM
Key Responsibilities:
- Develop, establish, and maintain robust manufacturing process parameters for ceramic fiber paper/mat production.
- Monitor and optimize critical process parameters such as: Fiber length and fiber preparation, Fiber dispersion, Slurry consistency, additive dosage, Fiber pulp formulation, Fiber washing/mixing conditions, pressing/dewatering conditions, Line speed, Drying temperature, Heat Treatment/Calcination, Heat Press settings.
- Identify process parameter variations affecting product quality and establish appropriate controls.
- Develop and maintain process specifications, operating standards, SOPs, and work instructions.
- The candidate should be capable of identifying the relationship between raw material characteristics, process parameters and final product properties.
- Process Control & Troubleshooting: Monitor critical process parameters and establish appropriate operating windows. Investigate process abnormalities related to: Thickness variation, Density variation, Weight variation, LOI variation, Strength variation, Moisture variation, Fiber distribution, Binder distribution, Surface defects, Delamination, Cracking/tearing, Dimensional variation
- Conduct systematic root-cause analysis using tools such as: 5 Why, Fishbone/Ishikawa, Pareto analysis, Process capability, Trend analysis, DOE, where applicable. Implement corrective and preventive actions and monitor effectiveness.
- Yield & Cost Improvement: Drive raw material yield improvement and reduction of process scrap. Analyze material consumption and identify opportunities to reduce: Fiber loss, Binder loss, Trim/waste, Rejection, Rework, Energy consumption.
- Lead cost-saving projects related to process optimization, tooling, raw material utilization, packaging and productivity.
- Establish and monitor manufacturing KPIs such as: Yield %, Rejection %, Productivity, OEE, Downtime, Material consumption, Conversion cost, Energy consumption
- New Product / Process Development: Support development and industrialization of new ceramic fiber paper/mat products. Conduct manufacturing trials for: New raw materials, New binders, New fiber grades, New sheet sizes, New process parameters, New tooling/dies. Document trial results and recommend optimized process parameters. Work closely with R&D, Quality and Engineering teams during product/process development. Support scale-up from laboratory/pilot trials to commercial production.
- Quality Improvement: Work closely with the Quality team to reduce customer complaints and internal rejection. Support investigation of customer complaints and preparation of RCA/8D/CAPA. Develop process controls to prevent recurrence of quality issues. Ensure critical-to-quality parameters are identified and controlled. Participate in internal, customer and supplier audits as required.
- Team & People Management: Lead and develop production operators, technicians and line leaders. Provide training on: Process parameters, Standard work, Quality requirements, Defect identification, Machine operation, Safety.
Qualifications/ Experience:
- Bachelor’s degree in Chemical/Ceramic/mechanical / industrial / manufacturing / production engineering (or equivalent).
- Experience (e.g. 3-7 years, adjust per seniority) in paper or ceramic fiber industry.
- Strong understanding and experience with process documentation tools: PFD, Flow Charts, FMEA, Control Plan, SOPs, Cycle time study, capacity planning etc.
- Experience in process design , new product development, process validation, design of experiments.
- Skills in equipment selection, commissioning & qualification.
- Familiarity with Lean Manufacturing, Six Sigma tools / continuous improvement methods.
- Strong problem-solving capability, root cause analysis.
- Good CAD skills (for tooling / layout), ability to interpret engineering drawings / tolerances (GD&T).
- Data analysis skills: SPC, process capability, cycle time analysis.
- Good project management: planning / scheduling / coordinating with multiple functions.
- Good communication skills; ability to work cross-functionally.
- Knowledge of safety, health, environmental standards relevant to manufacturing.
- Able to work with minimal supervision, prioritise workloads, meet deadlines and communicate effectively at all levels (Essential)
- Familiar with a Global Organisational Structure (Desirable)
- Experience in the manufacturing processes of non-woven needle punched fabrics, and secondary processes such as wet treatments and laminations (Desirable)
If you are interested in being part of a world class Manufacturing Engineering team here at Alkegen Pune Plant then we would love to hear from you.
At Alkegen, we strive every day to help people – ALL PEOPLE – breathe easier, live greener and go further than ever before. We believe that diversity and inclusion is central to this mission and to our impact. Our diverse and inclusive culture drives our growth & innovation, and we nurture it by actively embracing our differences and using our varied perspectives to solve the complex challenges facing our changing and diverse world.
Employment selection and related decisions are made without regard to sex, race, ethnicity, nation of origin, religion, color, gender identity and expression, age, disability, education, opinions, culture, languages spoken, veteran’s status, or any other protected class.
