KEY RESPONSIBILITIES:

Process/Product Monitoring -

 Ensuring Quality sustenance/improvements through audits with respect to process/product standards.

 Ensuring no variation/violence of specifications/guidelines at units
 Conducting Quality System audit and driving improvements in QA system
 Monitoring & improving on internal rejection/scrap.
 Monitoring field rejection (before usage, Premature & claim) & driving improvement projects
 Conduct field visit to get feedback & driving product improvements based on customer feedback

QA System & Training

 Imparting QA system & Problem-solving training

 Support to units for preparing process FMEA, Control Plan & SOP.\
 Driving Poka-yokes/Engineering controls
 Driving SPC implementation/improvements
 Driving Quality system implementation / QBM at outsourcing unit
 Liaising with customers for customer specific requirement of QA and implementing at unit

Customer Complaint handling -

 Customer complaints resolution with effective interactions with all stake holders
 Customers visits for better understanding of problem and effective communication on actions taken

Improvements -

 Driving QCDSM improvement projects with major focus on quality improvements

 Supporting units with stratification/analysis of data and failed parts to arrive at root cause & solutions

New Process/Product -

 Ensuring smooth introduction of new product & ensure effective change management process
 Homologation/Certification -

 Ensuring compliance to market/customer specific homologation/certification requirements

FUNCTIONAL competencies -

• Knowledge of 2/3 wheeler Tyre Manufacturing process( Foundational)

(process knowhow & ability to understand production processes, systems, layout plans and quality
measures)

• Proficiency in Plant systems & processes (Capable)

(Ability to implement QA system, 5S, FMEA/Control plan, QBM and other contemporary systems &
process.)

• Business Focus (Foundational)

(Knowhow on organizational mission ,Code of conduct, product SKU’s, accountabilities w.r.t market
scenario & competition & ability to apply in one's role, profitability )

• Customer Orientation (Capable)

(Cultural orientation to engage with customers, proactively assess their needs and continuously create
value for them)

• Data Interpretation Ability (Advanced)

(Ability to study & interpret data/trends and draw inferences/projections)

NPD

 No. of productivity and process improvement

 Quality Rating Score

 Adherence to NPD release conformances for new product release plan at plant
 Enhancement in Technical economy through technical cost optimization

 Reduction in overall process scrap, bladder cost & indirect material cost
 No. of Projects (Kaizens & QIPs)

Functions And Responsibilities

Operational Activities

NPD and Maintenance of Product, Process parameters

·Provide timely assistance in Product and Process development and Implementation at plants
·Conduct NPD trials as per the schedule and ensure that the trials are run as per the precise specifications
prescribed by the R&D team

·Guide the operations team including the shop floor operators in executing technical trials on the shop floor

·Effectively record and analyze trial results

Plant Support

 Ensure systematic execution of product and process checking and reviewing as per preset standards

 Manage inspection of machines to ensure uniformity in compliance and standards

 Conduct regular checks and engage in follow-ups for running trails at plants

 Assistance in smooth execution and timely completion of checks and audit of machine

 Conduct continual and regular safety and health condition checks and ensure maintenance of safety standards

 Continually track and monitor quality ratings for the assigned division and support the operations team is

systematically resolving manufacturing issues for enhanced quality ratings

 Conducting test-check audits at laboratories to ensure standardization

 Assistance in arrangement of necessary and required samples for the Research and Development department

 Accepting specifications of materials and making arrangements for requisition of required materials

 Ensuring proper coordination with the stores department and conducting follow-ups regarding new materials, or

materials ordered for trials and testing

 Attend regular meetings conducted by the internal team, as well as daily work management meetings, and ensure
representation of technical facts and insights at the same

Trouble Shooting
 Managing in a timely manner processing issues during trials and actual production and ensuring that the same shall

be efficiently handled and resolved

 Engaging in troubleshooting activities from time to time, to ensure production time conservation
 Ensure regular follow-ups for resolving of issues

Process Improvements and Changes

 Ensure execution of changes pertaining to new product development

 Ensure thorough handover and review of specification changes to the operator level at the plant

 Ensure continuous review and improvement in analytical and developmental activities

 Review of production related activities and ensuring their optimisation for overall cost saving

 Under the guidance of the superiors in the team, propose changing of compounds, changing of weights, etc. to

ensure cost reduction in existing products

 Continually engage in review and improvement of existing processes and resolving process issues

Technical Process Analysis

 Conduct a detailed analysis of defective materials or products

 Analysis of held-up batches at or during production, as well as at the time of disposition, with a view to ascertain its

causes and solutions

 Ensure analysis of minute aspects pertaining to scrap materials

 Analysis of compound scrap and determining factors behind the same

Documentation

·Maintaining proper records for changes in specifications of processes, on SAP

·Ensuring proper execution of technological economy trials and preparation of compliance reports
·Conducting trials for new materials or materials from new suppliers and preparing compliance reports for the
same

·Meticulous and regular updation of material specification changes on SAP

·Preparation of requisite monthly reports on Improvement activities (eg. Kaizen, 5S, etc.), Unsafe Conditions,
etc.

TECHNICAL
 PROCESS & PRODUCT:

 Optimize the use of existing material / alternate material for cost/rationalization/process benefit
 Analyze product failure due to manufacturing process variations and take necessary improvement
measures
 Responsible for all the technological activities at the designated area.
 Industrialize of new sizes as per time line- Annual NPD plan
 Review of key product and process parameters and initiate actions.
 Product and process quality improvement.
 Generate quality improvement projects to improve the product performance and process efficiencies
 System implementation, monitoring and control.
 PDCA approach to continual improvement for Productivity, Quality, waste reduction etc.

1. TECHNICAL ECONOMY:

 Product specification optimization in the designated area.

1. CLAIMS & LOSSES:

 Monitor process rework and scrap and maintain plant indicator within target limit .

1. TECHNICAL & QUALITY TASKS:

 Provide technical know-how and inputs to the designated sections.

 Analyse TBB/ Non Truck process variations and take necessary countermeasures

 Analytically sound to analyse the data & should retrieve any statistical data available in the system.
 Knowledge of strip winder based on profiles received from Tyre engineers/ Design team.
 Good knowledge in sub assembly, building and curing process trials and tooling management.
 SAP knowledge
  Proficiency in Tyre Manufacturing Technology (Capable)

(Technical knowhow ( Tyre/Heat engineering Calculations) & ability in

designated process, production processes, systems, layout plans and quality
measures)

 Proficiency in Plant systems & processes (Foundational)

(Ability to understand & implement 5S, safety practices, production best

practices, QBM and other contemporary systems & process.)

 Business Focus (Foundational)

(Knowhow on organizational mission ,Code of conduct, product SKU’s,

accountabilities w.r.t market scenario & competition & ability to apply in
one's role, profitability )

 Customer Orientation (Foundational)

(Cultural orientation to engage with customers, proactively assess their

needs and continuously create value for them)

 Data Interpretation Ability (Capable)

(Ability to study & interpret data/trends and draw inferences/projections)

MANAGERIAL  Analytical (Advanced)
COMPETENCIES
(Analyze issues and break them down to component parts. Makes
systematic and rational judgments based on relevant information’s)

 Decisive (Capable)

(Demonstrates readiness to make decisions, takes the initiative and

originates actions)

 Strategic (Foundational)

(Demonstrates a broad-based view of issues, events and activities and

perceives their longer term impact or wider implications)

 Organized (Capable)
 (Organize and schedule events, activities and resources. Set-up and monitor
time scales and plans)

 Coordinating (Capable)

(Motivates and empowers others in order to reach organizational goals,

Inter departmental coordination’s)

Proficiency Levels for Competencies:-

Basic- elementary understanding & familiarity

Foundational- ability to apply knowledge in certain areas

Capable- solid understanding and ability to apply knowledge in most areas

Advanced- Thorough in-depth understanding

Master- Advisory Expert in subject knowledge

NPD

Key Purpose of the Job (Position Summary)

This position is responsible for executing assigned Process Development (new or existing) activities to
ensure timely completion of all activities through coordination with all concerned departments. The
position is also responsible for documenting all the trial data and compiling various reports for analysis.

KEY PERFORMANCE AREAS

 Spec preparation of machines for development trials.
 Commissioning trials of new machines.
 Planning and execution of development trials.
 Documentation of trials with validation reports.
 Development of draft SOPs, Work Instructions and other standards.
 Value engineering activities.
 Maintenance of machines.
 Ensuring good housekeeping of the work stations.
 Know sheet and lessons learnt documentation.

KEY ACTIVITIES & RESPONSIBILITIES

Process Development

 Participate in meetings with Manager, Process development and assist in preparation of trial plans.
 Collect data required for finalising the trial proposals.
 Coordinate to arrange all resources like materials, machines, tools, etc for executing development
trials as per plan.
 Co-ordinate testing of in- process / finished products from each machine/process. Compile the results
and keep in a manner for accessing it easily in future.
 Monitor despatch / receipt of various components, tooling etc
 Document all trial details.
 Prepare draft SOPs, WIs and standards for review and finalisation.

Project activities

 Spec preparation of various machines and new processes being developed.

 Monitoring the timelines for different milestones.
 Execute commissioning trials and sign off activities.
 Coordination with various CFTs to ensure timely and successful execution of trials.

Machine / plant maintenance

 Ensure proper 5S for the R & D plant.

 Ensure preventive and corrective maintenance of machines.
 Other activities

 Conduct desk research for capturing the industry trends.

QUIALITY

KEY RESPONSIBILITIES:

Process/Product Monitoring -

 Ensuring Quality sustenance/improvements through audits with respect to process/product standards.

 Ensuring no variation/violence of specifications/guidelines at units
 Conducting Quality System audit and driving improvements in QA system
 Monitoring & improving on internal rejection/scrap.
 Monitoring field rejection (before usage, Premature & claim) & driving improvement projects
 Conduct field visit to get feedback & driving product improvements based on customer feedback

QA System & Training

 Imparting QA system & Problem-solving training

 Support to units for preparing process FMEA, Control Plan & SOP.\
 Driving Poka-yokes/Engineering controls
 Driving SPC implementation/improvements
 Driving Quality system implementation / QBM at outsourcing unit
 Liaising with customers for customer specific requirement of QA and implementing at unit

Customer Complaint handling -

 Customer complaints resolution with effective interactions with all stake holders
 Customers visits for better understanding of problem and effective communication on actions taken
 Improvements -

 Driving QCDSM improvement projects with major focus on quality improvements

 Supporting units with stratification/analysis of data and failed parts to arrive at root cause & solutions

New Process/Product -

 Ensuring smooth introduction of new product & ensure effective change management process

Homologation/Certification -

 Ensuring compliance to market/customer specific homologation/certification requirements

FUNCTIONAL competencies -

• Knowledge of 2/3 wheeler Tyre Manufacturing process( Foundational)

(process knowhow & ability to understand production processes, systems, layout plans and quality
measures)

• Proficiency in Plant systems & processes (Capable)

(Ability to implement QA system, 5S, FMEA/Control plan, QBM and other contemporary systems &
process.)

• Business Focus (Foundational)

(Knowhow on organizational mission ,Code of conduct, product SKU’s, accountabilities w.r.t market
scenario & competition & ability to apply in one's role, profitability )

• Customer Orientation (Capable)

(Cultural orientation to engage with customers, proactively assess their needs and continuously create
value for them)

• Data Interpretation Ability (Advanced)

(Ability to study & interpret data/trends and draw inferences/projections)

 NPD

Key Responsibilities :

o To capture customer requirements both for replacement market and identify new product
development or existing product improvement needs.
o Identify and do bench mark tyre analysis for New product development and improvement of existing
products.
o Market visit , meeting with customers , Market analysis and understanding of product performance
requirements and gaps.
o Incorporate inputs from market visits, competitor activities analysis and customer sales feedback in
developing more application based products within set timelines.
o Analysis of claims , generate monthly claim analysis report and do failed tyre analysis to identify
improvement opportunities for existing products .
o Initiate development projects for new products based on the market gaps or improvement projects
for existing products.
o Tech review meeting with Marketing and QA and sign off specification
o Lead NPD CFT meetings and review of progress
o Organize and coordinate with the testing team for indoor and outdoor test requirements of OEM
o Coordinate with various internal agencies for homologation of tyres. Initiate and organize
homologation and certifications for new products
o Develop the test procedures and performance requirements as per OE requirements
o Evaluate products on the field through ‘Product evaluation centers’, through testing team and collect
feedback.

QUALITY

KEYPERFORMANCE AREAS
· Ensure 100% compliance to process audit plan
· Ensure parameter wise analysis of non compliance.
· Ensure internal cure tyre defect reduction
· Ensure improvement in 5S Score
· Ensure reduction in Tyre Weight Variation
· Ensure reduction in Compound Held up

KEY ACTIVITIES & RESPONSIBILITIES

Operational
· Develop and implement quality control and inspection
procedures for in - process quality assurance across various
production lines in line with Quality standards and processes
prescribed
· Review day to day inspections and tests conducted in each shop
and conduct periodic sample checks
· Review recurring issues and plan for corrective actions
· Take shift handover and plan for smooth functioning of the shift
· Provide instructions to shift auditors incase of special follow ups.
· Review all log books and ensure conformance with SOPs
· Conduct daily rounds of the shop floor to track abnormalities.
· Conduct regular rounds in Raw Material and Finished Product
stores to ensure quality standards are maintained.
· Attend various meetings such as DWM, rejection meetings, SPC
discussions etc
· Conduct risk analyses, verification, validation activities, and
formal design reviews, as applicable
· Ensure adherence to quality norms and take corrective action
where necessary.
· Review warranty parts analysis and customer complaints and
recommend suitable action
· Address customer complaints leading to warranty claims due to
gaps in production processes through study, in-depth analysis, process
improvements, tools and other techniques
· Interact with shop floor workmen, ensure & promote quality &
right methods of working
· Analyze deviations and defects; find root causes, understand
patterns, initiate corrective action or escalate, as appropriate
· In case of process deviations, ensure line is stopped and the
required parts are quatarantined for further analysis
· Review rejections on the line, including rejections during set ups
and ensure appropriate corrective actions
· Review Root Cause Analysis reports of any non conformities to
assess the causes and the resolutely action taken
· Monitor and evaluate safety practices and procedures.
Audit, Inspection and Compliances

· Prepare an Audit calendar and routinely conduct audits to ensure

compliance to the prescribed standards.
· Document any discrepancies found and initiate corrective action
· Anchor for any external audit with auditors from customers, ISO,
OHSAS, etc.
· Ensure all audits are conducted smoothly and all finding acted
upon
· Monitor and ensure achievement of desired quality of product in
each stage of production process.
· Monitor the testing of various raw materials including rubber,
nylon, consumables for the plant.
MIS and Reports

· Ensure SAP is updated regularly.

· Develop, implement, and maintain procedures, flow chart
diagrams, and documentation to meet the requirements of TS16949,
ISO14001, and Customer Specific Requirements
· Conduct analysis such as reject tyre analysis, scrap analysis,
critical parameter analysis, tyre weight analysis, premature analysis,
non conformance analysis and prepare reports.
· Prepare documents to ensure critical issues, test failures are
captured, as necessary
· Ensure documentation of various BIS and ISO 9000 related
compliances.