Position: Mechanical Engineering Manager - NPI/NPD
Work Location: Hyderabad
Industry: Electronics Manufacturing Services (EMS)
Position Summary:
We are seeking an experienced and highly motivated NPI Mechanical Engineering Manager to lead the industrialization, assembly excellence, reliability engineering, and manufacturing readiness of aerospace-grade motor assemblies and electro-mechanical systems. This is a critical leadership role responsible for driving New Product Introduction (NPI) programs from design transfer through production ramp-up while ensuring compliance with aerospace quality, reliability, and regulatory standards.
The ideal candidate will possess deep expertise in precision motor assembly, electro-mechanical system integration, aerospace manufacturing, tooling development, quality systems, supplier development, and cross-functional team leadership. The role requires a hands-on engineering leader capable of solving complex technical challenges, driving operational excellence, and supporting customers and suppliers throughout the product lifecycle.
Key Responsibilities:
1. Electro mechanical Assembly Expertise
- Lead manufacturing and assembly of high-precision aerospace motors, including:
- BLDC / AC / DC motors
- Servo motors / actuators
- High-speed rotating systems
- Deep understanding of:
- Rotor-stator assembly alignment
- Dynamic balancing (G-level accuracy)
- Bearing selection, preload, lubrication techniques
- Winding processes, insulation systems, varnishing
- Address critical parameters:
- Runout, concentricity, vibration limits
- Thermal expansion & heat dissipation
- Noise and performance stability
- Ensure compliance with aerospace tolerances and traceability requirements
2. Electro-Mechanical Systems Integration
- Manage full assembly lifecycle of electro-mechanical products, including:
- Motors + Controllers + Harnessing + Sensors
- Integration challenges:
- EMI/EMC considerations
- Thermal and structural interactions
- Precision fitment of mechanical + electrical interfaces
- Validate system-level performance under:
- Vibration, shock, thermal cycling
- Endurance / life-cycle testing
3. Advanced NPI & Industrialization
- Lead end-to-end aerospace NPI programs:
- Design transfer → Proto → EVT / DVT / PVT → Mass production
- Drive:
- DFM / DFA optimization
- Manufacturing readiness reviews (MRR)
- Risk mitigation plans (DFMEA / PFMEA)
- Establish:
- Process flow diagrams, control plans, work instructions
- Ensure readiness for:
- AS9100 audit compliance
- First-time-right production
4. Engineering Drawings & CAD Mastery
- Expert-level capability in CAD drawing reading and interpretation:
- GD&T (ASME Y14.5 standard preferred)
- Tolerance stack-up analysis
- Critical-to-function feature identification
- Ability to:
- Identify manufacturability risks directly from drawings
- Suggest design corrections for assembly feasibility
- Work with tools:
- Creo / NX / SolidWorks
- Drive engineering change management (ECR/ECO)
5. Tools, Jigs & Fixture Development (Critical Skill Area)
- Design and validate:
- Assembly fixtures (alignment, press-fit tools)
- Coil winding fixtures
- Rotor balancing setups
- Knowledge of:
- Pneumatic / hydraulic tools
- Torque control systems
- Automated assembly stations
- Focus on:
- Error-proofing (poka-yoke)
- Repeatability & precision
- Cycle time reduction
6. FAIR, Quality & Aerospace Compliance
- Lead FAIR (First Article Inspection Report) execution as per AS9102
- Strong exposure to:
- AS9100, NADCAP (preferred)
- Drive:
- APQP, PPAP (adapted for aerospace)
- Control of special processes
- Perform:
- Root cause analysis (8D, Fishbone, 5 Why)
- Failure investigations (fractography, wear analysis, misalignment)
7. Supplier Development & Field Problem Resolution
- Extensive travel to supplier and customer locations for:
- Process audits
- Technical issue resolution
- Qualification activities
- Manage:
- Supplier capability assessments
- Critical component validation (laminations, bearings, shafts)
- Act as technical leader in:
- Customer escalations
- On-site troubleshooting of assembly failures
8. Team Leadership & Execution Excellence
- Lead cross-functional teams:
- Mechanical / Manufacturing / Quality engineers
- Drive:
- Performance management
- Capability building (technical mentoring)
- Establish:
- Strong engineering governance
- Structured problem-solving culture
Required Qualifications
- B.E / B.Tech / M.E in Mechanical Engineering
- 15 to 20 years in:
- Aerospace / defense / high-reliability EMS
- Motor assembly and electro-mechanical systems
- NPI and manufacturing engineering
Critical Technical Competencies
- Aerospace motor assembly fundamentals
- GD&T mastery & tolerance stack analysis
- FAIR (AS9102), APQP, PPAP
- Fixture/tooling design and validation
- Failure analysis & reliability engineering
- Supplier development and audits
- Lean manufacturing & Six Sigma
