Process Engineer BIW

Transport is at the core of modern society. Imagine using your expertise to shape sustainable transport and infrastructure solutions for the future. If you seek to make a difference on a global scale, working with next-gen technologies and the sharpest collaborative teams, then we could be a perfect match.

What you will do

Responsible for developing, industrializing, stabilizing and continuously improving BIW manufacturing processes for truck cabs, ensuring safety, quality, productivity, cost competitiveness and timely delivery of new products.

The role will work closely with Product Engineering, Production, Quality, Maintenance, Tooling, Automation, Industrial Engineering and Suppliers to establish robust BIW processes from concept through SOP and volume production.

Key Responsibilities

BIW Process Engineering

• Develop manufacturing processes and operation sequences for truck cab BIW.
• Define welding, joining, assembly and inspection processes.
• Prepare and maintain Process Flow, PFMEA, Control Plan and Standard Work.
• Establish optimum process parameters and ensure process capability.
• Identify and eliminate process bottlenecks and sources of variation.

BIW Welding & Joining

• Develop and optimize spot welding, MIG welding, stud welding, riveting and other joining processes.
• Define welding parameters and ensure consistent weld quality.
• Resolve welding defects such as missing welds, spatter, burn-through, distortion and weak welds.
• Improve welding productivity, quality and process reliability.

Fixtures, Tooling & Equipment

• Develop concepts and specifications for BIW fixtures, jigs, gauges and tooling.
• Review fixture designs for datum strategy, locating, clamping, accessibility, ergonomics and fool-proofing.
• Participate in tooling design reviews, trials, buy-off and commissioning.
• Ensure tooling capability meets dimensional and production requirements.

Industrialization & Continuous Improvement

New Product Introduction / Industrialization

• Lead BIW manufacturing activities for new truck/cab programs.
• Review product designs with manufacturability perspectives.
• Coordinate prototype, pilot and pre-production builds.
• Lead tooling and equipment readiness activities.
• Ensure BIW manufacturing readiness against project milestones.
• Support successful SOP and production ramp-up.

Automation & Industry 4.0

• Identify opportunities for automation and semi-automation.
• Support implementation of:
  • Robotic welding
  • Automated material handling
  • Vision systems
  • Sensors and process monitoring
  • Error-proofing / Poka-Yoke
  • Traceability systems
• Drive digitalization and data-based process improvement.

Productivity & Continuous Improvement

Drive improvements in:

• Cycle time study
• Line balancing
• Process efficiency
• Energy consumption
• Process reliability

Apply Lean Manufacturing, Kaizen, VSM, TPM and structured problem-solving to eliminate waste and improve process performance.

Production & Quality Support

• Provide technical support to BIW production for daily manufacturing issues.
• Resolve chronic process and dimensional problems.
• Conduct shop-floor process audits.
• Ensure adherence to standard processes and parameters.
• Drive reduction in welding defects, dimensional defects, rework and scrap.
• Support internal/customer quality audits.
• Implement effective Poka-Yoke and process controls.

Supplier & Project Management

• Coordinate with fixture, tooling, automation and equipment suppliers.
• Review supplier technical proposals and designs.
• Participate in FAT, SAT, trials and commissioning.
• Monitor supplier activities against project milestones.
• Ensure timely delivery of tooling and process equipment.

Competencies & skills

Technical Competencies

Essential:

• BIW manufacturing and assembly processes
• Truck cab / sheet-metal manufacturing
• Spot and MIG welding
• BIW fixtures, jigs, gauges and tooling
• GD&T and dimensional control
• BIW geometry and variation management
• PFMEA, Control Plan and Process Flow
• Root Cause Analysis
• Line balancing and capacity planning
• Lean Manufacturing / Kaizen

Preferred:

• Robotic welding and automation
• Industry 4.0 / smart manufacturing
• CAD interpretation - CATIA / NX / AutoCAD
• Statistical Process Control
• Experience with automated BIW lines

Qualification & Experience

Education:

• B.E./B.Tech in Mechanical, Automobile or Industrial Engineering

Experience:

• Typically 8-10 years of relevant BIW / Process Engineering experience, preferably in Commercial Vehicle manufacturing
• Experience in truck cab BIW, new model industrialization, robotic welding and fixture development.

Location : Hoskote

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Who we are and what we believe in

We are committed to shaping the future landscape of efficient, safe, and sustainable transport solutions. Fulfilling our mission creates countless career opportunities for talents across the group’s leading brands and entities.

Applying to this job offers you the opportunity to join Volvo Group. Every day, you will be working with some of the sharpest and most creative brains in our field to be able to leave our society in better shape for the next generation. We are passionate about what we do, and we thrive on teamwork. We are almost 100,000 people united around the world by a culture of care, inclusiveness, and empowerment.

Trucks Technology & Industrial Division hire team players who are ready to create real customer impact. Our decentralized teams work close to our customers, with speed and autonomy, to build what they truly need.

Join us to collaborate on innovative, sustainable technologies that redefine how we design, build, and deliver value. Bring your curiosity, your expertise, and your collaborative energy, and together, we’ll turn bold ideas into tangible solutions for our customers and contribute to a more sustainable tomorrow.