Advanced Manufacturing Engineer

Job Title: AME

Experience: 8-12 Years

Qualification: B.E. / B.Tech (Mechanical / Industrial / Automobile)

Industry: Automotive Manufacturing Industry

Job Location: Hosur

Description

New Product Introduction (NPI) Powertrain

• Lead manufacturing readiness for new engine, transmission powertrain programs.
• Drive APQP elements: PFMEA, Process Flow, Control Plans, and Work Instructions.
• Participate in DFM/DFMA reviews to ensure manufacturability of castings, machined components, and assemblies.
• Validate and launch new machining lines, assembly stations, and end-of-line testing equipment.
• Co-ordination with Cross functional teams for development of Industrialization studies for new programs
• Ensure the MPRQ - Manufacturing Process Readiness Qualification for new studies
• Lead for Change Management execution & controller for UPE function.

Process Development & Optimization

• Develop advanced processes such as CNC machining, honing, grinding, gear hobbing/shaping, heat treatment, leak testing, torque-to-turn, and automated assembly.
• Conduct cycle-time studies, line balancing, bottleneck analysis, and optimize throughput.
• Improve OEE, reduce scrap, improve Cpk and reduce process variation.

Tooling, Fixturing & Automation

• Design and specify cutting tools, fixtures, gauges, end-effectors, torque tools, and automated handling systems.
• Lead installation, commissioning, and validation of new equipment such as:
• Automated Engine & transmission assembly cells
• Robotic handling systems
• Precision machining centers
• End-of-line dynamometers or emotor testers
• Work with suppliers for tool trials, capability studies, and PPAP qualification.

Quality & Compliance

• Lead root-cause analysis for powertrain defects using 7QC tools, DMAIC, 8D, etc.
• Implement robust quality checkpoints: torque audits, leak tests, NVH checks, gear contact pattern tests.
• Ensure compliance with automotive standards: IATF 16949, ISO 14001, ISO 45001.

Continuous Improvement & Cost Reduction

• Lead Lean initiatives: SMED for tool changeovers, 5S audits, Kaizen workshops.
• Drive cost reduction in machining, tooling wear optimization, automation ROI, and material utilization.
• Implement digital manufacturing tools (Industry 4.0, OEE monitoring, predictive maintenance).

Documentation & Training

• Prepare SOPs, Work Instructions, PokaYoke documentation, and maintenance schedules.
• Train operators, supervisors, and maintenance teams on new processes and technologies.

5. COMMUNICATIONS & WORKING RELATIONSHIPS:

• Support COC assembly & machining and production work groups for short- and long-term improvement of the workstation and continuously improve the process automation levels to support to enhance the in process manufacturing quality.
• Perform Gemba (tour de terrain) in the area under control daily.
• Organize meetings with cross function team members to share & align on all proposal before final implementation
• Work in cross-functional teams: customer, supplier, Manufacturing engineering, Quality Department and others when needed.
• Use and demonstrate proper communication etiquette.
• Ensure effective communication with all concerned functions

6. Performance INDICATORS (INDICATIVE):

MANAGEMENT OF KEY METRICS:

• Custodian of assembly & machining related Advanced Manufacturing Engineering
• MPRQ - Manufacturing Process Readiness Qualification for new studies
• Automations Level standards
• Benchmark study solution implementations.
• Poka Yoke Implementations

DATA ACCURECY:

• Real time update of Flow charts/standards
• Accurate Flow/Process Automation/ Budget estimations
• Publishing of required study reports as required
• Manage the proper allocation of resources requirements and budget for the area. Ensure all required flow/ automations studies conducted appropriately.

TEAM DEVELOPMENT:

• Coach, train and develop Team Leaders for continuous improvement activities
• Create a good working environment in which everyone is treated with dignity and promote good working relationship, while developing engagement of all Team Members.
• Understand the overall social climate and improve
• Ensure Latest Techniques/tools to evaluate all type of flows

7. QUALIFICATIONS, eXPERIENCE & SKILLS:

QUALIFICATIONS:

• Bachelor of Engineering ( Production, Automobile, Mechanical) with 08-12 Years relevant experience in AME function for Engine & Transmission manufacturing functions in Automotive manufacturing industry

TECHNICAL SKILLS:

• Experience in Industrialization of new program studies
• Deep Knowledge on Power Train assembly & machining process
• Knowledge on Sealant Dispensing, Toolings, Test Facilities , Layout , Vison systems ,Engine/ Transmission assembly , Maintenance , Project Management ,Infrastructure , Facility, Building Design, Supplier selection, Installation , Cost Management
• Basic Knowledge of CNC Programming Fanuc and siemens control.
• Experience of working with Large Horizontal boring machines, Vertical lathes, Vertical milling machines.
• Experience in installation of Washing machines/Leak Testing/Press machines/VSVG/CH Sub assy equipments
• Knowledge of latest fixture designs, Tooling and its cutting parameters
• Proficient in using software such as AUTOCAD, CATIA, SolidWorks, etc.
• Awareness of ISO standards like QMS, EMS, EHS.
• Strong Knowledge of Documentation E.g. PFMEA, PFC WI, System Procedure
• General technical understanding of all Lean Manufacturing Tools/Techniques
• Proficiency in computer skills, specifically with tools and software defined by Stellantis, such as:

- Microsoft Office

- SAP

- Other relevant tools and software

BEHAVIORAL SKILLS:

• Good Technical skills
• Innovative & Participative in Business work groups
• Proactive Approach
• Excellent communication and negotiation skills.
• Fluent in English is Mandatory
• Strong leadership and team management capabilities.
• Ability to work collaboratively across departments and with external suppliers.
• Detail-oriented with strong organizational and time management skills
• Good written and verbal communication skills.
• Ability to work in a team environment and collaborate effectively with other engineers.

8. COMPETENCIES, CORE VALUES, BEHAVIOURS: -

Core Competencies:

• New Program launch readiness & execution
• New Technology introduction & industrialization of new projects
• Problem Solving & Decision Making
• Analytical Skills & Data Management
• Communication & Team Collaboration
• Continuous Improvement

Core Values:

• Integrity
• Accountability
• Respect
• Customer First
• Teamwork
• Sustainability

Behavioural Attributes:

• Adaptability & Flexibility
• Strong Organizational Skills
• Conflict Resolution
• Leading by Example
• Resilient & Decisive