Job Description

Job Title: Industrial Engineer - Rail Components Manufacturing

Company: Frontier Alloy Steels Ltd. (FASL)

Location:

Paonta Sahib, Himachal Pradesh (primary), with occasional travel to Kanpur, Uttar Pradesh

Department: Operations / Industrial Engineering

Reporting To: Plant Head / Head - Operations

About Frontier Alloy Steels Ltd.

Frontier Alloy Steels Ltd. is a leading Indian foundry and railway component manufacturer, supplying couplers, buffers, bogies, steel castings, investment castings, and metal-bonded rubber products to Indian Railways, wagon builders, and heavy engineering customers. The company operates modern manufacturing facilities in Kanpur (U.P.) and Paonta Sahib (H.P.), with strong expertise in steel castings, rubber-bonded components, and precision machining for the rail sector.

Role Overview

The Industrial Engineer will drive productivity, cost reduction, and process excellence across FASL's foundry, rubber, machining, and assembly operations. The role is hands-on and plant-focused, responsible for analysing current processes, designing improved methods, supporting Industry 4.0 initiatives, and ensuring that operations run safely, efficiently, and in line with Indian Railways/RDSO quality expectations.

Key Responsibilities

1. Study, map, and optimise end-to-end manufacturing processes (steel castings, bogies, couplers, draft gears, metal-bonded rubber, investment castings, machining, and assembly).

2. Conduct time & motion studies, work measurement, and line balancing to improve throughput and reduce bottlenecks.

3. Analyse machine, manpower, and line capacity; recommend capacity augmentation or re-balancing as demand scales.

4. Design and implement SOPs, work instructions, and visual controls for all critical processes and workstations.

5. Lead Lean/Kaizen projects: 5S, waste elimination, layout optimisation, SMED (setup reduction), scrap/rejection and rework reduction.

Support digital / Industry 4.0 projects: online production reporting, OEE/downtime tracking, and integration with dashboards/ERP/MES.

Work with Quality to analyse defects and failures, run root-cause analysis (5-Why, Fishbone), and implement CAPA.

Collaborate with Design/R&D and Production for industrialisation of new products - routing, cycle time, process capability, and manufacturability.

Drive cost reduction (material yield, energy, tooling, consumables) and support accurate process costing for tenders and quotations.

Improve layout, ergonomics, and safety in foundry, fettling, machining, and rubber shops in line with EHS norms.

Prepare and maintain process documentation: PFMEA, control plans, capacity sheets, WI/checklists, and training material.

Track and present key KPIs (OEE, productivity, utilisation, scrap, rework, on-time delivery) to plant and management.

Mentor and train supervisors/operators on basic IE and continuous improvement concepts (for senior candidates).

Required Qualifications

B.Tech / B.E in Industrial Engineering, Production Engineering, Mechanical Engineering, or equivalent;

OR M.Tech in Industrial / Production / Manufacturing Engineering.

Experience

5 to 20 years of experience in a heavy engineering / automotive / rail / foundry / fabrication / rubber moulding / casting / machining environment.

Experience in rail components, foundry, or rubber-bonded parts manufacturing will be a strong plus.

For higher-experience candidates, proven track record of leading IE / CI projects and influencing cross-functional teams is expected.

Interested candidates can send their resumes at hroffice.poanta@frontieralloy.com , frontierhrunit1@gmail.com or WhatsApp -92185-44306

Job Type: Full-time

Pay: ₹50,000.00 - ₹70,000.00 per month

Benefits:

Health insurance
Work Location: In person