Senior Methods Engineer – Mechanical

POLMOR STEEL PRIVATE LIMITED is seeking an experienced Senior Methods Engineer – Mechanical to manage manufacturing master data and process excellence at its Telangana manufacturing facility. The role focuses on Bill of Materials (BOM) preparation, routing creation, operation time calculation, and SAP PP (Production Planning) module activities, along with process standardization and continuous improvement. The position plays a key role in accurate production planning, costing, capacity utilization, and shop-floor efficiency, aligned with global standards.

Key Responsibilities

1. BOM, Routing & Operation Time

Management (SAP PP)·      Prepare, validate, and maintain Bill of Materials (BOMs) for manufactured and fabricated components

·      Create and maintain manufacturing routings, operation sequences, and work centers

·      Calculate and establish standard operation times, cycle times, and manpower norms

·      Ensure accuracy of standard times for costing, scheduling, and capacity planning

·      Maintain BOMs and routings in SAP PP with proper revision and change control

2. SAP PP (Production Planning)·      Create and manage BOMs, Routings, Work Centers, and Production Versions in SAP PP.

·      Support production order creation, scheduling, and execution

·      Assist in MRP runs, capacity evaluation, and production planning

·      Coordinate with production, stores, and costing teams to ensure master data accuracy

·      Ensure data integrity and adherence to SAP PP best practices

3. Methods & Process Engineering·      Develop and standardize manufacturing methods, process flows, and layouts.

·      Prepare process sheets, SOPs, and control plans

·      Conduct time & motion studies, line balancing, and capacity analysis

·      Provide shop-floor support for process stabilization and improvement

4. Continuous Improvement & Cost

Control·      Drive Lean Manufacturing, Kaizen, and productivity improvement initiatives

·      Identify opportunities for cycle time reduction, waste elimination, and cost savings

·      Support accurate product costing through validated BOMs and standard times

5. New Product Introduction (NPI)·      Support new product introduction and industrialization activities.

·      Conduct and participate in PFMEA and process risk assessments

·      Coordinate with design, quality, and production teams during NPI phase.

6. Quality, Safety & Compliance·      

Ensure compliance with ISO standards, safety norms, and statutory requirements

·      Support internal, external, and customer audits with required documentation

·      Reduce scrap, rework, and process deviations through robust methods

7.

Cross-functional & Global Coordination·      Work closely with production, quality, maintenance, supply chain, and SAP teams

·      Coordinate with global counterparts for process alignment and best practices

·      Train and guide junior engineers and supervisors on methods engineering and SAP PP usage.

Behavioral & Leadership Skills·

      Strong analytical and problem-solving skills

·      Excellent communication and coordination abilities

·      Hands-on and execution-focused approach

·      Ability to work independently and mentor teams

Required-Experience·  

.     8–12 years of experience in methods engineering / process engineering.

·      Strong hands-on experience in BOM preparation, routing definition, and operation time setting

·      Mandatory experience in SAP PP (Production Planning)

·      Experience in steel manufacturing, fabrication, welding, machining, or heavy engineering environments.