Sr. Engineer (New Product) Manufacturing Engineering

About the Role

We are looking for a Sr. Engineer NPI / Manufacturing Engineering to drive end-to-end manufacturing engineering execution for NPI Assembly and Heavy Fabrication/Welding projects, ensuring fixture, tooling, gauge, proto/pilot part and manufacturing readiness from drawing release through SOP.

The role will independently manage multiple NPI projects, drive cross-functional execution and ensure On-Time NPI delivery, robust manufacturing processes and timely gate sign-offs.

Qualification: B.E./B.Tech – Mechanical / Production / Industrial / Automobile / Manufacturing Engineering

Your Task

1. Own end-to-end NPI manufacturing engineering execution from drawing release / virtual build through proto, pilot build and SOP, managing 56 NPI projects per quarter.
2. Lead DFM/DFA and manufacturability reviews for assembly, fabrication and welding, converting findings into process, tooling and manufacturing improvements.
3. Design/review 2D & 3D assembly fixtures, welding/fabrication fixtures, jigs, gauges, poka-yoke and special tools, including datum, locating, clamping, tolerance, accessibility and distortion-control requirements.
4. Coordinate with Tool Room, suppliers and vendors for fixture/tooling fabrication, trials, corrections, validation and release, ensuring readiness before proto/pilot builds.
5. Drive proto and pilot part readiness, including critical fabricated, machined, bought-out and assembly parts; manage shortages, deviations, recovery actions and part follow-up.
6. Ensure NPI gate readiness and sign-off covering process, tooling, gauges, part readiness, documentation, capacity and manufacturing readiness requirements.
7. Lead proto/pilot build preparation and closure of fitment, welding, dimensional and assembly issues through root-cause analysis, containment and permanent corrective actions.
8. Develop and maintain Process Flow, operation sequence, workstation concepts, SOP/WI, PFMEA and Control Plan inputs, including capacity and cycle-time assessment.
9. Drive critical-path tracking, NPI dashboards, gate checklists, tooling/part readiness trackers, issue aging and risk management, with timely escalation and recovery planning.
10. Work closely with R&D, Production, Quality, SCM, Purchase, Tool Room and suppliers to ensure project delivery, while mentoring GET/DET/Junior Engineers and driving NPI lessons learned and continuous improvement.

Your Profile

1. 510 years of experience in NPI / Manufacturing Engineering / Manufacturing Engineering Department (MED), preferably in heavy engineering, construction equipment, earthmoving machinery or Automotive OEM/Tier-1.
2. Strong hands-on experience in NPI industrialization, virtual build, proto build, pilot build, SOP readiness and NPI gate management.
3. Strong knowledge of Assembly and Heavy Fabrication/Welding processes, including fit-up, dimensional control, welding sequence and assembly sequence.
4. Proven capability in fixture, tooling and gauge design/review, including assembly fixtures, welding/fabrication fixtures, jigs, gauges, poka-yoke and special tools using 2D/3D CAD.
5. Strong ability to read and interpret engineering drawings, GD&T and tolerance stack-up, with practical application in manufacturing and dimensional control.
6. Working knowledge of DFM/DFA, PFMEA, Process Flow, Control Plan, SOP/WI, manufacturing risk identification and process readiness.
7. Strong NPI project management, milestone tracking, critical-path management, risk management, CFT coordination and On-Time Delivery capability.
8. Experience in supplier/tool-room coordination, tooling trials, validation, part follow-up, issue closure and recovery planning.
9. Knowledge of ERP/SAP, DWM/RRR dashboards, NPI trackers and visual project management is desirable.
10. Strong shop-floor problem-solving and communication skills; Tamil & English proficiency required, Hindi desirable. Willingness to travel up to 10% for suppliers, plants and project requirements.