Converting Line Design & Systems Engineering Lead

Role: Senior Engineer

Required Skills: Value Stream (Agile)

Qualification: BACHELOR OF COMPUTER SCIENCE

Experience: 8 - 20 Years

Function: TECHNOLOGY

Apply By: 2026-11-20

Must Have Technical/Functional Skills

1. Possess E3 level competency in Manufacturing System Engineering involving

a. Converting Lines and associated Bill of Process

b. Typical Converting Line processes like Unwinding, splicing, threading, web Handling, Web Tension Control, slitting, various types of coating, curing, cutting, attacking and primary / secondary / Tertiary packaging.

c. Line design with right number of stations meeting the throughput.

d. Workstation design with line side storage

e. Line side storage trolley design

f. Line side replenishment strategy (Overhead conveying / Manual movement with FLT / AGV or AMR based)

g. Estimation of line side replenishment frequency

h. Specification development for the tools, assembly & inspection aids for each station

i. Conveying system design / specification development with type of conveying system & conveyor speed

j. Equipment for the converting processes and the suppliers of this type of equipment

k. Error proofing interlock design

l. Decision on manual / automation in converting operations

m. Estimation of FTE count

n. Estimation of utilities (WAGES) requirement at station level

o. Assessment of HSE fulfilment

p. MHE / part loading aids design

q. Knowledge on Advanced Modeling and Simulation to the extent of providing the right inputs to the Modeling and Simulation SMEs, providing inputs on various What-If Scenarios, Ability to interpret the Simulation Results and take corrective action in the Design

r. Providing inputs for control system engineering, sensorization, Plant IT system integration, sequencing, data acquisition, inventory tracking, QMS integration etc

s. Line Layout Design

2. Providing inputs / details to the CAD Design Engineers

3. Providing inputs for

a. Material flow simulation

b. Discrete event simulation

c. Station level process simulation / Ergo simulation

4. Providing inputs for Automation (Robotics / AGV, AMR / Vision System)

5. Line Redesign / improvements based on the simulation outcomes

6. Knowledge of CAD software platforms as well as Simulation platforms

7. Knowledge of the concepts of Value Stream Mapping

8. Experience in working with line builder / e quipment suppliers and technology OEMs

9. Exposure to AI / GenAI (Not mandatory)

10. Knowledge of Certification requirements in different regions

11. Experience in getting the equipment certified working with 3rd party agencies

Roles & Responsibilities

1. Requirement Analysis & definition

2. Work package / scope definition

3. Customer interactions & interactions with the Plant leadership

4. Estimation of effort and Schedule

5. Solutioning specific to line engineering and design

6. Working with Simulation team and other stakeholders including line builders / OEMs

7. Customer reviews

8. Project delivery

9. Organize & Schedules weekly calls with Customer & TCS Offshore team

10. Leading Installation / Commissioning and final handover at Customer site

11. Provide technical support to customer technicians/ engineers after the successful deployment of line design.

12. Continuously mining new opportunities across various areas within the plant & other sites and developing proactive solutions (may need to visit other sites)

Generic Managerial Skills, If any

Action oriented - Taking on new opportunities and tough challenges with a sense of urgency, high energy, and enthusiasm.

Collaborates - Building partnerships and working collaboratively with customer/Vendors to meet shared objectives.

Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences.

Salary Range: $100,000 - $140,000 per year

TCS Employee Benefits Summary:

Discretionary Annual Incentive.

Comprehensive Medical Coverage: Medical & Health, Dental & Vision, Disability Planning & Insurance, Pet Insurance Plans.

Family Support: Maternal & Parental Leaves.

Insurance Options: Auto & Home Insurance, Identity Theft Protection.

Convenience & Professional Growth: Commuter Benefits & Certification & Training Reimbursement.

Time Off: Vacation, Time Off, Sick Leave & Holidays.

Legal & Financial Assistance: Legal Assistance, 401K Plan, Performance Bonus, College Fund, Student Loan Refinancing.