Senior Manufacturing Engineer New Product Development

Position Title
Senior Manufacturing Engineer New Product Development
Department
Manufacturing Engineering
Reports To
Manufacturing Engineering Manager

Position Summary
We are seeking a highly experienced and results-driven Senior Manufacturing Engineer with deep expertise in Machining, Gear manufacturing & Assembly processes to lead new product planning and process development, optimization, and continuous improvement initiatives. The ideal candidate will possess extensive knowledge on process planning, programming, tool selection, fixture designing, troubleshooting, improving process capability, quality standards, and continuous improvement in a high-precision components manufacturing environment.
This role will be responsible for developing robust manufacturing processes, reducing cycle times, improving quality, supporting new product introduction (NPI), and ensuring compliance with customer specifications and industry standards.
Key Responsibilities
Manufacturing Process Engineering

• Plan, design, develop, implement, and optimize manufacturing processes for machining (Turning, Milling-3 to 5 Axis) and gear manufacturing processes
• Establish process, programme, fixture and tooling strategies
• Analysis and troubleshooting issues to improve product quality and productivity
• Lead process validation, capability studies, and first-article approvals for new products.
• Create and maintain process documentation, work instructions, setup sheets, PFMEA, control plans, and standard operating procedures.
• Collaborate with tooling suppliers to evaluate new cutting technologies and process improvements.
• Support machine commissioning, qualification, and production ramp-up activities.
• Lead Lean Manufacturing, Six Sigma, and Kaizen initiatives focused on productivity, quality, and cost reduction.

Quality & Compliance

• Ensure manufactured gears meet customer drawings, AGMA, DIN, ISO, JIS, and internal quality requirements.
• Support quality investigations for non-conformances, corrective and preventive actions.
• Work closely with Quality Assurance teams on PPAP, APQP, MSA, SPC, and capability studies.
• Participate in customer audits and technical reviews.

New Product Introduction (NPI)

• Review product designs for manufacturability and provide DFM recommendations.
• Support prototype development and production launch activities.
• Estimate manufacturing costs, cycle times, and resource requirements for new programs.
• Coordinate with design, quality, maintenance, and production teams to ensure successful product launches.

Technical Leadership

• Mentor junior engineers, technicians, and machine operators.
• Provide technical guidance on manufacturing best practices.
• Lead cross-functional problem-solving teams and process improvement projects.
• Stay current with advancements in manufacturing technology and industry trends.

Required Qualifications
Education

• Bachelors Degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related discipline.

Experience

• 10+ years of manufacturing engineering experience in precision component and gear manufacturing.
• Expertise in gear manufacturing background will be an added advantage
• Experience in NPD planning and FAI development is mandatory

Technical Skills
Essential

• Expert knowledge of:
• Gear Hobbing
• Gear Shaping
• Turning & Mill turn
• Milling-3 to 5 axis
• Cylindrical Grinding
• Splines
• Gear Tool selection
• Gear Metrology

• Strong understanding of:
• AGMA, DIN, ISO gear standards
• GD&T interpretation
• Cutting tool technology
• Fixture design
• Process planning
• Tool selection

• Experience with:
• Gear inspection equipment
• Statistical Process Control (SPC, Cp/Cpk)
• PFMEA, Control Plans, APQP, PPAP, FAI

What Success Looks Like
Within the first 12 months, the successful candidate will:

• Improve gear hobbing and shaping process efficiency and capability.
• Reduce manufacturing defects and process variation.
• Improve the FAI TAT

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