Continuous Improvement Analyst
Vertiv · Pune
Job Description – Production Supervisor
XDU/CDU End-of-Line Testing Production Supervisor
Company: Vertiv Location: Chakan Plant, Pune, India Department: Production / Manufacturing Reports To: Production Manager Employment Type: Full-Time
We are seeking an experienced and technically proficient CDU (Coolant Distribution Unit) End-of-Line Testing Supervisor to lead and manage the end-of-line testing operations for our CDU production line. The ideal candidate will bring deep expertise in liquid cooling systems, chilled water systems, and automated testing equipment, combined with strong supervisory and production management skills. This role is critical to ensuring every CDU leaving the production line meets stringent quality, performance, and safety standards.
- Supervise and execute end-of-line testing of Coolant Distribution Units (CDUs) used in data centre liquid cooling applications
- Operate, program, and troubleshoot automated test equipment (auto testers) designed for CDU functional and performance validation
- Conduct and oversee water pressure testing including hydrostatic testing, leak testing, and pressure decay testing as per established procedures and standards
- Read, interpret, and validate readings from instrumentation including pressure transducers, temperature sensors (RTDs, thermocouples), flow meters, differential pressure gauges, and other water system instruments
- Ensure proper functioning and calibration of all test instruments and equipment
- Validate CDU components and sub-assemblies including butterfly valves, ball valves, control valves, coupling joints (Victaulic/grooved couplings), heat exchangers, pumps, manifolds, and piping assemblies
- Understand and apply knowledge of chilled water system principles — flow dynamics, pressure drops, heat rejection, temperature differentials, and coolant loop operations
- Diagnose and resolve test failures by analyzing root causes related to hydraulic, mechanical, or electrical sub-systems of the CDU
- Maintain and update test procedures, checklists, and acceptance criteria documentation
- Enforce and ensure strict adherence to electrical safety protocols during CDU testing (lockout/tagout, grounding, insulation resistance testing, high-voltage precautions)
- Enforce and ensure strict adherence to mechanical safety protocols (pressurized system handling, PPE compliance, safe coupling/decoupling of water lines, spill containment)
- Conduct risk assessments and ensure all testing activities comply with EHS (Environment, Health & Safety) standards
- Maintain safety records, incident reports, and ensure corrective actions are implemented promptly
- Ensure compliance with relevant industry standards and regulatory requirements for pressure vessel and water system testing
- Supervise, mentor, and train a team of testing technicians and operators on CDU testing procedures, instrument handling, and safety practices
- Develop and maintain operator certification and skill matrix programs for the testing team
- Conduct regular performance reviews, provide feedback, and identify skill development needs
- Plan and manage shift schedules, manpower allocation, and workload distribution to meet production targets
- Coordinate with production planning to align testing schedules with production targets and delivery timelines
- Monitor and report key metrics — first pass yield (FPY), test cycle time, defect rates, and throughput
- Drive continuous improvement initiatives to reduce test cycle times, improve yield, and enhance testing reliability
- Maintain 5S standards on the testing shop floor — Sort, Set in Order, Shine, Standardize, Sustain
- Adhere to and promote standard manufacturing practices including lean manufacturing, Kaizen, and visual management
- Coordinate with cross-functional teams including Design Engineering, Quality, Manufacturing Engineering (ME), Advanced Manufacturing Engineering (AME), Supply Chain, and Service for issue resolution and process improvements
- Participate in new product introduction (NPI) activities by supporting test procedure development and validation for new CDU models
- Manage test equipment maintenance schedules and coordinate with vendors for calibration and servicing
- Bachelor's Degree in Engineering — Mechanical, Electrical, Mechatronics, or a related discipline
- Minimum 5 years of hands-on experience in testing, quality, or production supervision roles in a manufacturing environment
- Demonstrated experience with liquid cooling systems, chilled water systems, or HVAC systems
- Proven experience with pressure testing procedures (hydrostatic, pneumatic, leak detection)
- Experience working with automated test systems/auto testers in a production environment
- Strong working knowledge of chilled water system components — valves (butterfly, ball, control), coupling joints, heat exchangers, pumps, expansion tanks, and piping systems
- Proficiency in reading and interpreting P&ID (Piping & Instrumentation Diagrams) and engineering drawings
- Ability to read, calibrate, and troubleshoot instruments — pressure transducers, temperature sensors (RTDs/thermocouples), flow meters, differential pressure gauges, and data loggers
- Understanding of electrical systems in CDUs — control panels, VFDs, sensors, and wiring
- Familiarity with test automation software/platforms and data acquisition systems
- Knowledge of relevant standards (ASME, ASHRAE, ISO) related to pressure testing and water systems
- Proven ability to lead, train, and develop a team of technicians and operators
- Strong understanding of production scheduling, manpower planning, and resource optimization
- Experience in maintaining quality standards in a production/testing environment (ISO 9001 awareness preferred)
- Hands-on experience with 5S implementation and shop floor discipline
- Familiarity with lean manufacturing principles, Kaizen, and continuous improvement methodologies
- Excellent coordination and communication skills for cross-functional collaboration
- Proficiency in MS Office (Excel, Word, PowerPoint) and familiarity with ERP/MES systems
- Experience specifically in data centre cooling equipment manufacturing or testing
- Exposure to CDU, in-row cooling, or precision cooling product lines
- Knowledge of data centre infrastructure and liquid cooling architectures (direct-to-chip, rear-door heat exchangers, immersion cooling)
- Certification in Six Sigma (Green/Black Belt) or equivalent quality methodology
- Experience with SPC (Statistical Process Control) and test data analytics
- Familiarity with PLC-based test automation and SCADA systems
- Attention to detail and commitment to quality
- Strong analytical and problem-solving skills
- Safety-first mindset
- Ability to work under pressure and meet tight production deadlines
- Proactive and self-driven with a continuous improvement orientation
- Effective team leadership and people development skills
- Adaptability to a fast-paced, evolving manufacturing environment
Vertiv is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.