Job Summary
Dynamic Manufacturing Engineer with specialized expertise in integrating complex electrical systems and high-voltage battery assemblies for next-generation aircraft with Proven track record in bridging the gap between design and the shop floor through robust DFM/DFA strategies, IPC-compliant process development, and real-time troubleshooting. Expertise in scaling battery enclosure assembly, thermal management, and advanced wire harness routing from prototype to serial production in highly regulated aerospace environments.
Role & Responsibilities:
I. Design Integration & Strategy (The Before the Build Phase)
- Support DFM/DFA activities during design reviews to ensure the manufacturability and serviceability of complex electrical systems.
- Define wire routing strategies ensuring safety, serviceability, and strict compliance with aerospace standards.
- Collaborate closely with design, quality, and supply chain teams to optimize build flow and reduce cycle time from the outset.
- Work with suppliers and internal teams to validate battery module assembly techniques and specialized tooling.
II. Process Development & Documentation
- Develop and implement manufacturing processes for aircraft battery installation, including enclosure assembly, mounting, thermal management, and electrical interfacing.
- Create and validate build processes for wiring harness routing, terminations, and connector assemblies.
- Develop Standard Operating Procedures (SOPs), Manufacturing Instructions (MIs), and detailed inspection criteria.
- Manage production data, including MBOM (Manufacturing Bill of Materials) preparation, Process Flow Diagrams, Control Plans, and PPAP/FAI documentation.
III. Shop Floor Execution & Troubleshooting
- Provide hands-on support to technicians on the shop floor during both prototype and serial production phases.
- Troubleshoot wiring and battery integration issues in real-time, implementing immediate corrective actions to maintain build schedules.
- Support the creation of harness assembly boards, work instructions, and functional test procedures.
- Drive Root Cause Analysis (RCA) for non-conformances and lead continuous improvement efforts to prevent recurrence.
Technical Skills & Competencies
Electrical Mastery:
- Technical Drawing Fluency: Ability to read wiring harness drawings, circuit diagrams, connector views, and terminal callouts.
- Component Expertise: Deep understanding of wire grades/types, terminal selection, crimp specifications, sealing systems, splice methods, and protection standards (taping/sleeving).
- System Knowledge: Understanding of PCB interfaces, wiring harnesses, and busbar design.
Standards & Quality:
- Industry Standards: Good understanding of IPC/WHMA-A-620 (preferred), IPC-A-600/610, and IPC-7711C/7721C.
- Validation: Proficiency with crimp height charts and pull-force standards.
- Exposure to QMS standards AS9100D is preferred.
- Regulatory Familiarity: Familiarity with international standards (IEC, IS, UL, CE, RoHS, EMC/EMI).
Software & Systems:
- ECAD Tools: Exposure to harness design software (Capital, Zuken) is a significant advantage.
- CATIA Electrical harness module & PLM exposure is preferred
- MS office / Google suite proficiency
Qualifications :
- Bachelor's degree in Electrical, Electronics or any related field.
- 4+ Years of Experience in ME E&E Integration activities in Aerospace industry preferred.
Work Location: Kelambakkam, Chennai, Tamil Nadu, India.
Job Type: Full-time, Work from office. 
