Senior Process Specialist

Location: Doddaballapura

Job Description:

Senior Position in Solar Module Manufacturing

Role Overview :
Highly skilled and result-oriented position – Solar Manufacturing with 8+ years of experience in solar PV module manufacturing. Responsible for driving end-to-end production performance, ensuring process compliance, and maintaining consistent product quality. Demonstrated ability to coordinate across departments — including Quality, Maintenance, Engineering, and Planning — to meet customer expectations and achieve organization’s productivity, yield, and quality objectives.
Possesses strong technical expertise in process optimization, new product introduction, line balancing, and system documentation aligned with ISO, customer, and internal QMS requirements.

Key Responsibilities
1. Production Operations & Shift Management
Plan, execute, and monitor daily production activities across all process stages (stringing, layup, lamination, trimming, framing, testing, and packing).
Ensure adherence to daily production plans as per PPC schedule, managing manpower allocation, shift rotation, and resource planning.
Review and control production KPIs such as output, yield, rework %, and downtime.
Conduct Sunrise and Sunset meetings to track previous shift performance, discuss ongoing issues, and plan corrective actions.
Coordinate with the Maintenance & Engineering teams to minimize breakdowns and ensure maximum machine uptime.
Oversee implementation of FIFO systems, material traceability, and process discipline on the shop floor.
Ensure proper handling, storage, and use of raw materials (cells, glass, EVA, back sheet, ribbons, junction boxes, etc.) as per standards.

2. Process Control & Parameter Adherence
Monitor all critical process parameters at stringer, layup, and laminator sections to ensure stable output.
Perform in-process checks and review process data to identify trends or deviations.
Maintain and update process control sheets and parameter logbooks for traceability.
Lead troubleshooting activities for yield loss, delamination, or other process-related defects.
Collaborate with Engineering to define process window limits and conduct trials for process optimization.
Verify calibration and health status of critical instruments and jigs before start of production.

3. Quality Assurance & CAPA Support
Support the Quality team in analysing internal rejections and customer complaints to identify true root causes.
Prepare CAPA reports with complete root cause, corrective, and preventive action plans related to production.
Coordinate containment, segregation, and rework activities for defective materials or in-process issues.
Work closely with QA to implement process corrections and ensure recurrence prevention.
Participate and conduct MRM (Management Review Meetings) and CFT meetings to present production data and action status along with improvement plans.
Verify EL and Visual Inspection criteria preparation and adherence at each stage to ensure defect-free module output.

4. Documentation & QMS System Compliance
Prepare and maintain all production-related documentation such as:
Department Manual and Procedures
SOPs / Work Instructions / Process Flow Diagrams
Daily Process Logs / Parameter Sheets
Skill Matrix & Training Records
Deviation / CAPA / Audit Observation Reports
Support ISO 9001, ISO 14001, and ISO 45001 audit requirements for the production department.
Coordinate with QA for documentation related to customer audits.
Support preparation of Supplier Return Notes (SRN) for non-conforming materials.
Ensure document traceability and version control for all QMS documents related to production.

5. New Product, Line, and Equipment Development
Participate in new product development (NPD) and process qualification trials, ensuring smooth integration with production lines.
Lead machine validation and qualification activities for new Jinchen laminators, ATW stringers, and other equipment upgrades.
Support DOE (Design of Experiment) trials for process improvements and customer sample approvals.
Prepare trial reports, process validation data, and observation summaries for management review.
Drive standardization of new product processes into regular production with…