Manufacturing Engineer - Assistant Manager

Responsible for managing and executing new product development activities from concept to production, with a strong focus on sheet metal fabrication, MIG/TIG welding and heavy fabrication. The role involves process development, prototype development, technical coordination, manufacturability improvement, cost optimization and successful transition of new products to mass production.
Key Responsibilities
Lead and coordinate New Product Development (NPD) activities from RFQ/concept stage through prototype, validation and production launch.
Study customer drawings, specifications and technical requirements and evaluate Design for Manufacturability (DFM) and fabrication feasibility.
Develop manufacturing processes for sheet metal fabrication, MIG/TIG welding and heavy fabrication.
Review drawings, weld symbols, GD&T, material specifications and fabrication requirements.
Plan and coordinate prototype manufacturing, trial production and process validation.
Develop and optimize Welding Process Parameters for MIG and TIG applications.
Select suitable welding methods, consumables, fixtures and process sequences based on product requirements.
Develop Welding Fixtures, Jigs and Tooling to improve productivity, dimensional accuracy and repeatability.
Coordinate with Design, Production, Quality, Tool Room, Purchase and SCM teams for smooth NPD execution.
Identify and resolve technical issues related to welding defects, distortion, dimensional variation, fitment and fabrication processes.
Conduct process trials, feasibility studies, first-off inspections and prototype validation.
Prepare and maintain Process Flow Diagrams, PFMEA, Control Plans, Work Instructions, SOPs and process documentation.
Support development of BOM, routing, cycle time, manpower and process cost estimates.
Analyze manufacturing cost and identify opportunities for cost reduction and productivity improvement.
Ensure proper material selection and fabrication methods for mild steel, stainless steel and other applicable materials.
Coordinate with suppliers for outsourced fabrication, welding, machining and special processes where required.
Support APQP/PPAP activities and ensure timely submission of required NPD documents.
Monitor prototype and pre-production builds against project timelines and customer requirements.
Implement corrective and preventive actions for NPD-related quality and process issues.
Drive Kaizen, Lean Manufacturing, 5S, Poka-Yoke and continuous improvement initiatives.
Ensure compliance with company quality, safety and environmental standards.
Mentor and guide engineers, supervisors and technicians involved in NPD activities.
Technical Competencies
Strong knowledge of Sheet Metal Fabrication and Heavy Fabrication.
Good hands-on knowledge of MIG/MAG and TIG Welding processes.
Knowledge of welding parameters, consumables, weld defects and inspection methods.
Knowledge of jigs, fixtures, tooling and welding sequence development.
Ability to interpret 2D drawings, 3D models, GD&T and welding symbols.
Knowledge of fabrication processes such as cutting, bending, shearing, drilling, punching, grinding and welding.
Knowledge of WPS/PQR/WPQ and welding quality requirements.
Understanding of DFM/DFA, PFMEA, Control Plan and Process Flow.
Knowledge of APQP, PPAP, 8D, Root Cause Analysis and CAPA.
Familiarity with ERP/SAP systems and engineering documentation.
Knowledge of Lean Manufacturing, Kaizen and continuous improvement methodologies.
Qualification:
B.E./B.Tech/Diploma in Mechanical Engineering, Production Engineering, Manufacturing Engineering or a related discipline.
Experience:
Typically 10–14 years of relevant experience in New Product Development, Sheet Metal Fabrication, Welding or Heavy Fabrication, preferably in an automotive, engineering or industrial manufacturing environment.
Preferred Experience
Experience in developing products involving:
Sheet metal components and assemblies
MIG/TIG welded assemblies
Heavy fabrication structures
Welding fixtures and tooling
Prototype and trial production
Customer-specific fabricated components
Productionization and process stabilization

Work arrangement
No