Process Engineer - Defence & Aerospace

Role & responsibilities

The Lead Manufacturing Engineering will be responsible for developing, optimizing, and standardizing machining and assembly processes, including CAD/CAM programming, tooling strategies, process planning, and production readiness. The role will drive efficient manufacturing, cost reduction, and quality improvement while supporting new product Development (NPD) and production scaling.

This role requires strong expertise in Manufacturing parts estimations, Selection of Various m/c for Precision manufacturing, precision machining, fixture design, CAM programming, and assembly process engineering.

Key Responsibilities

1. Machining Process Planning

• Develop detailed machining process plans for precision components.
• Define operation sequences, machining strategies, and cutting parameters.
• Select appropriate machines, tools, and fixtures.
• Optimize cycle time, tool life, and machining efficiency.
• Support 5-axis, multi-axis CNC machining operations where applicable.
• Implement DFM (Design for Manufacturing) improvements.

2. CAD/CAM Programming

• Develop and validate CNC programs using CAD/CAM software Solid Works
• Generate tool paths, simulation, and verification.
• Optimize machining programs for cycle time reduction and quality improvement.
• Support post processor configuration and machine integration.
• Collaborate with design teams to ensure manufacturable designs.

Common tools may include:

• Solid Works
• SOLID CAM

3. Assembly Process Planning

• Define assembly processes and work instructions.
• Create assembly sequence planning and work breakdown structure.
• Develop assembly fixtures, jigs, and tooling.
• Establish torque specifications, fastening strategies, and tolerance stack-ups.
• Design ergonomic and efficient assembly lines.

4. Manufacturing Documentation

Develop and maintain:

• Process sheets
• GD&T
• Manufacturing work instructions
• Bill of Process (BOP)
• Standard operating procedures (SOPs)
• Tooling documentation
• Control plans

Ensure compliance with quality standards and regulatory requirements.

5. New Product Development (NPD)

• Lead manufacturing readiness for new products.
• Conduct process feasibility analysis.
• Support prototype manufacturing and pilot production.
• Coordinate first article inspection (FAI) activities.

6. Tooling & Fixture Development

• Design or coordinate design of machining fixtures and assembly jigs.
• Validate clamping methods and datum schemes.
• Improve fixture designs to enhance repeatability and precision.

7. Production Optimization

• Identify and implement cycle time reduction opportunities.
• Improve OEE (Overall Equipment Effectiveness).
• Lead lean manufacturing initiatives.

Apply:

• Kaizen
• Six Sigma
• Value Stream Mapping

8. Cross-Functional Collaboration

Work closely with:

• Design Engineering
• Quality Engineering
• Production
• Supply Chain
• Tooling teams

To ensure smooth product industrialization and production support.

Technical Skills

Manufacturing

• CNC machining (3-axis / 5-axis)
• Tooling and fixture design
• GD&T interpretation
• Tolerance stack-up analysis
• Process capability improvement

Manufacturing Systems

• ERP / MRP systems
• PLM systems
• Digital manufacturing tools

Preferred candidate profile

Education

Min. Bachelors or Master’s degree in:

• Mechanical Engineering

Experience

• 12–15 years in precision machining and assembly manufacturing.
• Experience in CNC machining, CAD/CAM programming, and process planning.
• Experience in aerospace, defense, or precision engineering industries preferred.