Key Roles & Responsibilities

1. Product & Process Engineering

- Review customer drawings, GD&T;, material specifications, and international standards, including DIN, ISO, and AGMA.
- Develop stage drawings, manufacturing process flows, and process plans for gears and splined shafts.
- Establish manufacturing processes for gear hobbing, shaping, shaving, broaching, grinding, turning, and related machining operations.
- Develop tooling plans for cutting tools, fixtures, broaches, hobs, gauges, and master gears.
- Evaluate material selection, forging processes, heat treatment, and their impact on dimensional accuracy and component distortion.

2. NPD, APQP & Quality Planning

- Lead all five phases of APQP and ensure timely completion of NPD milestones.
- Prepare and review PFMEA, Process Flow Diagrams, Control Plans, SOPs, and other technical documentation.
- Coordinate dimensional inspection, material validation, metallurgical testing, and process capability studies.
- Lead PPAP preparation and submission, ensuring customer approval before production release.
- Establish SPC practices and inspection methods using CMM, gear roll testers, profile testers, and specialized gauges.

3. CNC Machinery & Manufacturing Engineering

- Evaluate and select CNC turning centers, VMCs, HMCs, turn-mill centers, and specialized gear-cutting and grinding machines.
- Assess machine capability, kinematics, accuracy, tooling requirements, and suitability for complex gears and splined shafts.
- Review and optimize CNC programs, tool paths, and machining cycles across FANUC, Siemens, Mitsubishi, and Heidenhain control systems.
- Lead machine prove-outs, process validation, cycle-time optimization, and production line commissioning.
- Evaluate automation opportunities, including robotic loading, gantry systems, and material-handling solutions.

4. Industrial Engineering & Line Setup





- Design and implement manufacturing layouts for new product lines and production cells.
- Perform cycle-time analysis, takt-time calculations, and line balancing to improve productivity and throughput.
- Identify bottlenecks, reduce machine idle time, and optimize manpower, tooling, and equipment utilization.
- Ensure manufacturing processes meet customer requirements for quality, cost, delivery, and production capacity.

5. Project Management & Customer Coordination

- Independently manage international OEM projects from feasibility assessment to production launch.
- Act as the primary technical interface for overseas customers, handling engineering reviews, technical queries, and project updates.
- Coordinate with Design, Production, Quality, Purchase, Tooling, Maintenance, and other cross-functional teams.
- Monitor project schedules, technical deliverables, validation activities, and customer approval milestones.
- Proactively identify project risks and implement corrective and preventive actions.

6. Team Leadership & Production Handover

- Lead and mentor cross-functional engineering and NPD teams.
- Ensure operators and production personnel are trained on process requirements, SOPs, safety, and inspection methods.
- Establish process stability and ensure readiness for serial production.
- Complete the formal handover of validated manufacturing processes to the mass production team.

Essential Skills & Competencies

- Extensive experience in gear, spline, and shaft manufacturing.
- Strong knowledge of CNC machining and specialized gear manufacturing equipment.
- Expertise in APQP, PPAP, PFMEA, Process Flow, Control Plans, SPC, and GD&T.;
- Knowledge of forging, engineering materials, heat treatment, and metallurgical validation.
- Experience in tooling development, machine selection, line commissioning, and process optimization.
- Proven ability to manage international customer projects and cross-functional teams.
- Solid technical problem-solving, project execution, and communication skills.

📌 Engineering Manager (NPD) (India)
🏢 Saaki Argus And Averil Consulting
📍 India