Manufacturing Engineering Manager

Position: Mechanical Engineering Manager - NPI/NPD

Work Location: Hyderabad

Industry: Electronics Manufacturing Services (EMS)

Position Summary:

We are seeking an experienced and highly motivated NPI Mechanical Engineering Manager to lead the industrialization, assembly excellence, reliability engineering, and manufacturing readiness of aerospace-grade motor assemblies and electro-mechanical systems. This is a critical leadership role responsible for driving New Product Introduction (NPI) programs from design transfer through production ramp-up while ensuring compliance with aerospace quality, reliability, and regulatory standards.

The ideal candidate will possess deep expertise in precision motor assembly, electro-mechanical system integration, aerospace manufacturing, tooling development, quality systems, supplier development, and cross-functional team leadership. The role requires a hands-on engineering leader capable of solving complex technical challenges, driving operational excellence, and supporting customers and suppliers throughout the product lifecycle.

Key Responsibilities:

1. Electro mechanical Assembly Expertise

• Lead manufacturing and assembly of high-precision aerospace motors, including:
• BLDC / AC / DC motors
• Servo motors / actuators
• High-speed rotating systems
• Deep understanding of:
• Rotor-stator assembly alignment
• Dynamic balancing (G-level accuracy)
• Bearing selection, preload, lubrication techniques
• Winding processes, insulation systems, varnishing
• Address critical parameters:
• Runout, concentricity, vibration limits
• Thermal expansion & heat dissipation
• Noise and performance stability
• Ensure compliance with aerospace tolerances and traceability requirements

2. Electro-Mechanical Systems Integration

• Manage full assembly lifecycle of electro-mechanical products, including:
• Motors + Controllers + Harnessing + Sensors
• Integration challenges:
• EMI/EMC considerations
• Thermal and structural interactions
• Precision fitment of mechanical + electrical interfaces
• Validate system-level performance under:
• Vibration, shock, thermal cycling
• Endurance / life-cycle testing

3. Advanced NPI & Industrialization

• Lead end-to-end aerospace NPI programs:
• Design transfer → Proto → EVT / DVT / PVT → Mass production
• Drive:
• DFM / DFA optimization
• Manufacturing readiness reviews (MRR)
• Risk mitigation plans (DFMEA / PFMEA)
• Establish:
• Process flow diagrams, control plans, work instructions
• Ensure readiness for:
• AS9100 audit compliance
• First-time-right production

4. Engineering Drawings & CAD Mastery

• Expert-level capability in CAD drawing reading and interpretation:
• GD&T (ASME Y14.5 standard preferred)
• Tolerance stack-up analysis
• Critical-to-function feature identification
• Ability to:
• Identify manufacturability risks directly from drawings
• Suggest design corrections for assembly feasibility
• Work with tools:
• Creo / NX / SolidWorks
• Drive engineering change management (ECR/ECO)

5. Tools, Jigs & Fixture Development (Critical Skill Area)

• Design and validate:
• Assembly fixtures (alignment, press-fit tools)
• Coil winding fixtures
• Rotor balancing setups
• Knowledge of:
• Pneumatic / hydraulic tools
• Torque control systems
• Automated assembly stations
• Focus on:
• Error-proofing (poka-yoke)
• Repeatability & precision
• Cycle time reduction

6. FAIR, Quality & Aerospace Compliance

• Lead FAIR (First Article Inspection Report) execution as per AS9102
• Strong exposure to:
• AS9100, NADCAP (preferred)
• Drive:
• APQP, PPAP (adapted for aerospace)
• Control of special processes
• Perform:
• Root cause analysis (8D, Fishbone, 5 Why)
• Failure investigations (fractography, wear analysis, misalignment)

7. Supplier Development & Field Problem Resolution

• Extensive travel to supplier and customer locations for:
• Process audits
• Technical issue resolution
• Qualification activities
• Manage:
• Supplier capability assessments
• Critical component validation (laminations, bearings, shafts)
• Act as technical leader in:
• Customer escalations
• On-site troubleshooting of assembly failures

8. Team Leadership & Execution Excellence

• Lead cross-functional teams:
• Mechanical / Manufacturing / Quality engineers
• Drive:
• Performance management
• Capability building (technical mentoring)
• Establish:
• Strong engineering governance
• Structured problem-solving culture

Required Qualifications

• B.E / B.Tech / M.E in Mechanical Engineering
• 15 to 20 years in:
• Aerospace / defense / high-reliability EMS
• Motor assembly and electro-mechanical systems
• NPI and manufacturing engineering

Critical Technical Competencies

• Aerospace motor assembly fundamentals
• GD&T mastery & tolerance stack analysis
• FAIR (AS9102), APQP, PPAP
• Fixture/tooling design and validation
• Failure analysis & reliability engineering
• Supplier development and audits
• Lean manufacturing & Six Sigma