Dear Candidate,

Job Title: Process & Tool Design Engineer (Wind Turbine Gearbox), Pune Location.

Job Purpose

The Process & Tool Design Engineer standardizes assembly workflows and creates specialized mechanical tooling for multi-megawatt wind turbine gearboxes (WTG). This role ensures high-precision torque applications, safe handling of heavy multi-ton components, and flawless execution of complex interference fits. The engineer works to reduce assembly cycle time while maintaining strict safety, quality, and ISO 9001 standards.

Key Responsibilities

Assembly Process Engineering
- Develop Assembly Routing: Author detailed Standard Operating Procedures (SOPs), digital work instructions, and routing sheets for planetary, helical, and high-speed gear stages.
- Design Plant Layouts: Create and optimize floor layouts for assembly stations, heavy rigging, paint booths, and end-of-line test benches to minimize component travel.
- Manage Critical Joints: Define and control strict tightening processes for critical high-torque bolted joints,



utilizing hydraulic tensioners and calibrated DC electric torque tools.
- Implement Thermal Assembly: Establish accurate process controls for heating housings or induction-heating large bearings and gears to execute interference fits smoothly.

Tooling & Fixture Design
- Design Heavy-Duty Fixtures: Utilize 3D CAD software (SolidWorks, Creo, or CATIA) to develop robust assembly jigs, turnover fixtures, and alignment gear.
- Develop Lifting & Rigging Jigs: Engineer custom lifting beams, hooks, and shackle configurations for safely manoeuvring multi-ton castings, shafts, and completed gearboxes using EOT cranes.
- Conduct Tolerance Stack-Up: Perform comprehensive tolerance stack-up analyses and apply Geometric Dimensioning and Tolerancing (GD&T;) to ensure precision tooling fitment.
- Validate & Test Tooling: Execute structural calculations, Finite Element Analysis (FEA), and physical load testing to certify tooling safety factors before s

📌 Process & Tool Design Engineer -Wind Turbine Gearbox (Pune)
🏢 Pioneer Filmed
📍 Pune