Description

The Senior Manufacturing Tooling Engineer will be responsible for developing and implementing global tooling systems for engine component manufacturing within powertrain operations. The role focuses on delivering innovative tooling solutions, supporting current product launches, improving machining processes, and driving continuous cost and productivity improvements.

Working closely with Product Development, Manufacturing Engineering, Quality, Suppliers, and Plant Operations, the successful candidate will ensure tooling systems meet manufacturing, quality, safety, and operational requirements throughout the programme lifecycle.

The position requires expertise in cutting tool engineering, machining processes, supplier management, process optimisation, and advanced manufacturing technologies. The individual will also lead cross-functional teams during equipment commissioning, production launches, and process capability development while promoting Lean Manufacturing and continuous improvement principles.

Responsibilities

Tooling Engineering & Process Development

- Develop and implement global tooling strategies for manufacturing engine components.
- Design, specify, select, and optimise cutting tools, including drills, inserts, reamers, end mills, taps, broaches, and grinding tools.
- Evaluate manufacturing feasibility and support Design for Manufacturing and Assembly (DFMA) activities.
- Introduce advanced tooling technologies, tool management systems, minimum quantity lubrication (MQL), and process improvements.
- Establish and maintain tooling standards, cutting parameters, tool setup documentation, and engineering specifications.
- Monitor tool performance and implement actions to maximise tool life and process capability.

New Programme Launch Support

- Lead tooling activities during new product and programme launches.
- Develop tooling packages and technical specifications for suppliers.




- Support equipment build, installation, commissioning, validation, and manufacturing readiness activities.
- Conduct tooling trials, machine prove-out activities, and production validation.
- Coordinate cross-functional teams to ensure successful programme execution.

Supplier & Vendor Management

- Prepare and issue Requests for Quotation (RFQs) to tooling suppliers.
- Evaluate supplier quotations and conduct technical and commercial comparisons.
- Select suppliers and manage tooling procurement activities.
- Review tooling designs, layouts, drawings, and manufacturing processes with suppliers.
- Lead supplier audits, pre-runoff evaluations, and tooling acceptance activities.

Manufacturing Excellence & Continuous Improvement

- Analyse machining parameters, including cutting speeds, feeds, and depth of cut, to improve productivity and quality.
- Investigate tooling issues such as excessive wear, chatter, dimensional variation, and tool failures.
- Apply Lean Manufacturing and Six Sigma methodologies to reduce scrap, downtime, and tooling costs.
- Identify opportunities for process optimisation, standardisation, and cost reduction.
- Develop tooling master schedules and monitor project milestones.

Documentation & Compliance

- Lead development and maintenance of manufacturing process documentation, including:
- Process Failure Mode and Effects Analysis (PFMEA)
- Process Sheets
- Control Plans
- Work Instructions
- Tool Setup Documentation
- Process Illustrations





- Ensure timely delivery of tooling drawings, layouts, cycle-time studies, and supplier documentation.
- Support issue resolution during launch and production stabilisation phases.

Qualifications

Education

Required:

- Bachelor's Degree or Diploma in:
- Mechanical Engineering
- Manufacturing Engineering
- Production Engineering
- Industrial Engineering
- Automotive Engineering

Preferred:

- Master's Degree in Engineering or related discipline.

Experience

- 12 to 20 years of manufacturing engineering experience.
- Minimum 12 years of tooling engineering experience in machining operations.
- Experience supporting engine, powertrain, automotive, or precision-machining manufacturing environments.
- Experience leading new programme launches and production start-up activities.
- Experience managing tooling suppliers and external manufacturing partners.

Technical Skills

- Cutting tool design and application engineering.
- CNC machining and manufacturing process knowledge.
- Process optimisation and productivity improvement.
- Statistical Process Control (SPC).
- Root Cause Analysis and structured problem solving.
- Quality management systems and manufacturing standards.
- AutoCAD or equivalent CAD software.
- Tool management systems and tooling inventory control.
- Project management fundamentals.

Leadership Competencies

- Strong leadership and stakeholder management skills.
- Excellent communication and presentation abilities.
- Ability to lead cross-functional teams.
- Self-motivated with a proactive problem-solving approach.
- Adaptability and ability to work within global project environments.

Preferred Certifications

- Lean Manufacturing
- Six Sigma Green Belt or higher
- Project Management Certification (preferred)

Mobility

- Willingness to travel and relocate globally based on project and business requirements.

📌 Senior Manufacturing Tooling Engineer (Chennai)
🏢 Ford Motor
📍 Chennai