Senior Industrial Engineer
Sulzer · Pune
Sulzer is a leading engineering company with a proud heritage of innovation. Join our global team to grow your expertise and develop innovative solutions that enable a prosperous and more sustainable society.
About the role
Job SummaryThe Sr. Process Engineer is responsible for supporting the development and optimization of manufacturing processes. This role applies practical engineering knowledge to improve efficiency, quality, and safety in production environments.
This job profile is intended for experienced professionals who apply practical knowledge of a job area and work independently with general supervision.
Job Description: Senior Industrial Engineer
Job Title: Senior Industrial Engineer
Location
Sulzer Production Facility (Global/Regional Site)
Reporting To
Global Head Operations Excellence
Purpose of the Job
The Senior Industrial Engineer is responsible for driving operational excellence, productivity improvements, factory optimization, and manufacturing system design across Sulzer operations. The role combines industrial engineering expertise, lean manufacturing principles, digital manufacturing tools, and factory design methodologies to improve safety, quality, delivery, cost, and sustainability performance.
The position supports both local manufacturing operations and global operations initiatives through value stream optimization, standard work development, capacity planning, line balancing, factory layout design, and deployment of the Sulzer Excellence System (SES). The engineer will lead data-driven improvement projects and support the development of future-state manufacturing systems utilizing digital twins, simulation, and advanced manufacturing technologies.
Main Tasks and Responsibilities
Industrial Engineering & Operational Excellence
- Lead productivity improvement and cost reduction initiatives across manufacturing operations.
- Conduct time studies, motion studies, and video-based manufacturing method analysis using tools such as AVIX.
- Develop and maintain standard work instructions and work combination sheets.
- Perform line balancing and workload optimization to improve flow and labor efficiency.
- Calculate labour standards and manufacturing performance metrics.
- Analyse bottlenecks and implement sustainable corrective actions.
- Support capacity planning and resource optimization activities.
- Conduct overall equipment effectiveness (OEE) analysis and improvement projects.
- Utilize industrial engineering methodologies to improve throughput, quality, and operational performance.
Lean Manufacturing & Sulzer Excellence System
- Drive implementation of Sulzer Excellence System (SES) principles.
- Facilitate Value Stream Mapping (VSM) and future-state design workshops.
- Lead Kaizen, continuous improvement, and waste elimination initiatives.
- Implement pull systems, supermarket concepts, and material flow improvements.
- Support visual management, workplace organization, and 5S deployment.
- Develop and monitor KPI dashboards for operational performance.
- Coach production teams on Lean methodologies and problem-solving techniques.
Factory Design & Digital Manufacturing
- Create and maintain factory layouts and manufacturing line designs.
- Design factory and production flows using Visual Components and AutoCAD.
- Generate digital twins of manufacturing areas and production systems.
- Model equipment, fixtures, tools, lifting devices, and visual management solutions.
- Define material flow concepts and ergonomic workstation designs.
- Support simulation and validation of manufacturing concepts through digital modelling.
- Arrange production areas considering safety, infrastructure, and operational constraints.
Manufacturing Process Improvement
- Lead process optimization projects from concept through implementation.
- Conduct process failure mode and effects analysis (PFMEA).
- Develop process flow diagrams and manufacturing process maps.
- Identify opportunities for automation and semi-automation solutions.
- Support new product introductions through manufacturing readiness assessments.
- Establish manufacturing
Education
- Bachelor's or Master's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Production Engineering, Operations Management, or a related technical discipline
- Additional qualifications in Lean Manufacturing, Six Sigma, Operational Excellence, Ergonomics, or Project Management are advantageous
- Continuous improvement certifications (Lean Six Sigma Green Belt/Black Belt, Kaizen, Value Stream Mapping, etc.) preferred
Professional Experience
- Minimum 5-10 years of industrial engineering experience in a manufacturing environment
Proven experience driving productivity, efficiency, quality, and cost improvement initiatives in discrete manufacturing industries - Minimum 3-5 years of hands-on experience using Visual Components or equivalent manufacturing simulation software (Tecnomatix Plant Simulation, FlexSim, AnyLogic, etc.)
- Strong experience in work measurement, time studies, standard work development, line balancing, and labour optimization
- Demonstrated experience implementing Lean Manufacturing and Continuous Improvement methodologies across factory operations
- Experience with Value Stream Mapping, process optimization, capacity analysis, and bottleneck identification
- Experience integrating automation solutions into modelling, such as conveyor systems, overhead hanger systems, automated warehouses, AGVs, AMRs, and assembly processes.
- Experience supporting factory layout design, facility expansion, manufacturing transfers, or greenfield/brownfield projects
- Experience using manufacturing analytics and performance metrics to identify and execute improvement opportunities
- Experience facilitating Kaizen events, problem-solving workshops, and cross-functional improvement projects
- Exposure to automation, digital manufacturing, Industry 4.0, or manufacturing simulation tools such as Visual Components.
- Experience working within international and matrix organizations is desirable
Technical Skills
- Strong knowledge of Industrial Engineering principles and methodologies
Advanced knowledge of Lean Manufacturing, Operational Excellence, and Continuous Improvement tools - Strong understanding of manufacturing processes, material flow, ergonomics, and production systems
- Experience with Visual Components, Autodesk Inventor, AutoCAD, Factory Design Utilities, or equivalent design software
- Proficiency in Microsoft Office Suite, particularly Excel and Power BI for data analysis and reporting
- Experience with ERP systems (SAP preferred) and manufacturing execution systems (MES)
- Good knowledge of Value Stream Mapping and process mapping tools (Visio or equivalent)
- Knowledge of statistical analysis and problem-solving tools such as Minitab, SPC, FMEA, Fishbone Analysis, and 8D
- Strong understanding of health, safety, quality, and environmental requirements within manufacturing operations
Personal Competencies
- Excellent analytical and conceptual skills with the ability to understand complex manufacturing systems and operational challenges
- Strong data-driven decision-making capability and problem-solving mindset
High attention to detail and commitment to delivering quality results - Ability to challenge existing processes and drive innovative solutions
- Strong project management and organizational skills with the ability to manage multiple priorities simultaneously
- Ability to influence stakeholders and drive change across functions and sites
- Strong communication and presentation skills with the ability to engage teams at all organizational levels
- Self-motivated and capable of working independently with minimal supervision
- Results-oriented with a continuous improvement mindset and strong execution focus
- Excellent teamwork and collaboration skills within global and cross-functional environments
- Fluent in English, both written and spoken; additional languages are advantageous
What we offer you
Insurance benefits
Company transport
Sulzer is an equal opportunity employer. We believe in the strength of a diverse workforce and are committed to offering an inclusive work environment.
We are proud to be recognized as a Top Employer 2026 in Brazil, Canada, China, Finland, Germany, Ireland, Mexico, Switzerland, South Africa, the UK and the USA.