Manager - Mechanical NPI & Engineering

This role is a critical leadership position responsible for driving industrialization, assembly excellence, and reliability engineering of aerospace-grade motor assemblies and electro-mechanical systems.

The candidate must demonstrate deep domain expertise in precision motor assembly, aerospace standards, complex mechanical systems, and NPI execution, along with strong capability in team leadership, supplier collaboration, and customer-facing problem resolution.

Core Responsibilities (Detailed & Interview-Level Depth)

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

• 15–20 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