MANGAL INDUSTRIES LIMITED

Job Description

Deputy Engineer / Engineer - Welding Fixture & Jig Design and Manufacturing

1. Position Snapshot

Parameter

Details

Position Title

Deputy Engineer / Engineer - Welding Fixture & Jig Design and Manufacturing

Function / Department

Production / Fabrication

Business Unit

Metal Fabrication (sheet metal, tube and structural weldments)

Reports To

Fabrication Incharge

Grade Offered

Deputy Engineer (Diploma route) or Engineer (Degree route), based on qualification and demonstrated fixture portfolio

Qualification

DME (Diploma in Mechanical / Tool & Die / Production Engineering) - 4 to 5 years experience OR B.E. / B.Tech (Mechanical / Production / Industrial) - 3 to 4 years experience

Total Experience

3 to 5 years, of which minimum 2 years must be hands-on welding fixture and jig design in a multi-variant (high-mix, low-to-medium volume) fabrication setting

Position Type

Individual contributor with functional control over 2-3 fitters / fixture welders

Work Pattern

General shift, with shop-floor presence during fixture trials and new product launches occasional travel to customer and vendor locations

Positions Open

1 (to be filled within 45 days)

2. Purpose of the Role

Our fabrication shop runs a high-mix product basket in which the same welder handles several variants in a single shift. In this environment, output is lost not at the arc but before it - in part collection, locating, squaring, measuring and tacking. The single largest lever available to us is tooling: a well-designed welding fixture converts a skill-dependent setting operation into a load-and-clamp operation, moves quality upstream into the tool, and releases welder hours back to actual arc time.

This role owns that lever end to end. The incumbent will design, build, prove out and continuously improve welding fixtures, jigs, gauges and locating tooling for both existing and new products will own the weld map and welding parameter standard for each assembly and will be measured on the throughput, first-pass quality and dimensional capability that the tooling delivers on the shop floor - not on the number of drawings released.

3. Key Responsibilities

3.1 Welding Fixture and Jig Design

- Study customer drawings, 3D models, weldment BOM and process route for new and running jobs identify the datum scheme, critical-to-quality (CTQ) dimensions and tolerance stack-up before any fixture concept is drawn.
- Design welding fixtures, tack fixtures, sub-assembly jigs, checking gauges and drill/hole-location jigs using the 3-2-1 principle for rigid tube and structural parts, and the N-2-1 / RPS locating principle for sheet metal panels.
- Design deliberately for multi-variant families: common base plate, common clamp mounting pattern, interchangeable locator inserts and quick-change tooling plates so that model changeover is achieved in single-digit minutes rather than by building a new fixture per variant.
- Select and specify locating and clamping elements - rest pads, dowel and diamond pins, V-blocks, toggle clamps, cam clamps, pneumatic swing and power clamps, wedge and side-thrust units - with correct clamping sequence, clamping force and self-locking behaviour.
- Build distortion control into the design: weld sequence, balanced welding, pre-set camber and over-bend allowance, restraint versus free-shrinkage decisions, copper / chill backing bars, spatter-shielded and hard-faced locating surfaces.
- Ensure the fixture is welder-friendly and secure: torch access and gun angle at every joint, explicit line of sight to the arc, unobstructed part loading and free lift-out of the finished weldment, ergonomic load height, rotation / tilt where it removes overhead and vertical-up welding.
- Design poka-yoke into the tool - asymmetric locators, presence pins, mistake-proof stops and interlocks - so that a wrong child part, a mirrored left/right part or a reversed orientation physically cannot be loaded.
- Design fixtures for press-fit weld-nut and weld-stud stations (positional locators for nut and stud positions, electrode clearance, projection support) so that fastener position and perpendicularity are guaranteed by the tool.
- Perform fixture design review with production, quality and welding before release: fixture DFMEA, tolerance stack-up study, clash and access check, and where required simple FEA / deflection check on the fixture base and clamping structure.
- Fully exploit and standardise the shop's modular 3D perforated welding tables - design tooling around the existing hole grid, clamp and stop systems, and build a reusable modular element library instead of one-off welded steel structures wherever the volume justifies it.

3.2 Fixture Manufacturing, Trial and Commissioning

- Release complete manufacturing packages: fixture GA, detail part drawings with GD&T;, weldment drawings for the fixture base, standard-part BOM, surface treatment and hardness specification, and assembly instructions.
- Drive in-house fabrication and machining of fixtures through the tool room, and manage external tool-making vendors on cost, quality and delivery float enquiries, technically evaluate quotations and track the tooling budget against approved cost.
- Ensure fixture base stress-relieving / seasoning, machining of locating surfaces,



and hardening or hard-chrome plating of high-wear locators to protect long-term repeatability.
- Own fixture qualification: layout inspection of the fixture itself, tool try-out with actual child parts, first-article dimensional validation of the weldment on CMM / height gauge / checking fixture, capability confirmation on CTQ dimensions, and formal handover to production with a signed tool commissioning report.
- Establish preventive maintenance and calibration frequency for every fixture maintain the fixture master register with tool number, product family, location, revision status, spare locator stock and next due date drive fixture health audits on the shop floor.
- Manage the engineering change process - implement customer / internal design changes into existing fixtures with correct revision control, and prevent obsolete-fixture usage on the line.

3.3 Welding Knowledge and Weld Mapping

- Prepare and own the weld map for every weldment: a controlled drawing or exploded view in which every joint carries a unique weld ID, joint type and preparation, weld size and length, process, welding position, weld sequence number, and the inspection class applicable to that joint.
- Interpret and apply welding symbols to ISO 2553 / AWS A2.4, and translate customer weld callouts into shop-floor-usable weld maps and welder instruction sheets.
- Establish Welding Procedure Specifications (WPS) and supporting parameter standards for each material and thickness combination - process (GMAW/MIG-MAG, GTAW/TIG, SMAW, stud welding, projection and spot welding), wire and electrode grade and diameter, shielding gas and flow, current, voltage, wire feed speed, travel speed, heat input, stick-out and torch angle.
- Support welder qualification and periodic re-qualification, welder skill matrix maintenance, and structured on-the-job training so that the parameter standard is actually followed at the machine.
- Set and control weld quality acceptance: visual weld inspection standard, weld gauge usage, undercut / porosity / spatter / burn-through / lack-of-fusion criteria, throat and leg-length verification, and destructive checks (macro-etch, fillet break, nut and stud push-out and torque testing) at defined frequency.
- Work to and interpret the relevant welding codes and quality frameworks applicable to our products - AWS D1.1 (structural steel), AWS D1.3 (sheet steel), ISO 3834 quality requirements, and customer-specific welding standards.
- Drive weld cost and cycle-time reduction: eliminate over-welding against design requirement, right-size fillet legs, optimise intermittent versus continuous welds, improve deposition rate, and reduce rework and grinding hours.
- Support the introduction of semi-automatic and robotic welding - evaluate joints for automation, design fixtures with robot-compatible datum and clamping, and prepare weld maps in a form directly usable for robot program generation.

3.4 Productivity, Quality and Continuous Improvement

- Convert setting-bound operations into fixture-bound operations and demonstrate the resulting output gain in units per shift, with before-and-after time study evidence.
- Carry out line balancing and time-and-motion study around the new tooling: separate collection, setting, tacking, full welding and finishing eliminate welder idle time waiting on setting and rebalance manpower to the constraint.
- Lead root cause analysis and permanent corrective action on fabrication rejections and dimensional defects using 8D, why-why, fishbone and PFMEA, with fixture and weld-parameter countermeasures.
- Contribute to Kaizen, SMED changeover reduction, 5S and cost-reduction projects in the fabrication and welding area, with quantified savings.
- Support current product development and prototype builds: feasibility feedback on weldability and fixturability at the drawing stage (Design for Manufacturing input), fixture lead-time planning and launch readiness.

3.5 Documentation, Systems and Safety

- Maintain the complete tooling documentation set - fixture drawings, weld maps, WPS, control plan and PFMEA linkage, work instructions, tool history cards - under proper revision control.
- Operate within the plant ERP / SAP environment for tooling material reservation, purchase requisition, tool room work orders and maintenance notifications.
- Ensure every fixture and tooling design complies with plant EHS requirements: pinch-point guarding, safe lifting and handling provision above defined weight, pneumatic circuit safety, fume extraction access and arc-flash screening.

4. Skills and Competencies

4.1 Essential - the candidate must clear these

- Demonstrable portfolio of welding fixtures and jigs personally designed and successfully commissioned, with photographs or drawings the candidate can walk us through in the interview.
- Strong drawing reading and GD&T; interpretation ability to derive datums, tolerance stack-up and a defensible locating scheme from a customer drawing without hand-holding.




- 3D CAD proficiency for fixture design and detailing - SolidWorks (weldments, sheet metal, assembly, drawing) and / or Creo, NX, Inventor, plus AutoCAD for 2D.
- Practical welding knowledge in GMAW / MIG-MAG and GTAW / TIG on mild steel, and working knowledge of stainless steel and aluminium welding behaviour ability to read and write welding symbols and prepare weld maps.
- Working knowledge of the upstream process chain and how it affects weldment accuracy - laser cutting, CNC turret punching, shearing, press brake and panel bending, tube laser and tube bending, clinching and riveting.
- Hands-on measurement and validation capability: vernier, height gauge, bevel protractor, weld gauges, dial and lever indicators, and CMM report interpretation.
- Structured problem-solving discipline - 8D, why-why, PFMEA - and the willingness to stand at the machine until the fixture works.
- Communication in English and Telugu or Hindi sufficient to instruct welders and fitters directly on the shop floor.

4.2 Desirable - differentiators at selection

- Experience with modular fixturing systems (Siegmund, Demmeler, Bluco or equivalent perforated 3D welding tables) and with standard fixture components from DESTACO, Norelem, Kipp, Jergens or equivalent.
- Exposure to robotic and cobot welding cells and to fixtures designed for robot access and repeatability.
- Exposure to weld distortion simulation or FEA-based fixture deflection checking.
- Experience with pneumatic and hydraulic clamping circuit design.
- Familiarity with ISO 3834, EN 1090, AWS D1.1 / D1.3, or IATF 16949 documentation discipline.
- Certified Welding Inspector qualification (CWI / IWI / NDT Level II in VT or PT) or formal welding technology certification.
- Prior work in enclosures, cabinets, containers, racks, battery / energy-storage structures, EV structures, railway or heavy fabrication - product families close to our growth portfolio.

5. Performance Measures (First 12 Months)

Key Performance Indicator

Target

Review Cycle

Output improvement on fixtured jobs (units per shift versus baseline)

Minimum +100% on nominated bottleneck assemblies

Monthly

Setting time per assembly

Reduction of 60% or more against pre-fixture time study

Per project

Welder arc-on time in the fabrication cell

Improvement of at least 15 percentage points

Monthly

First-pass yield / dimensional rejection on fixtured weldments

Rejection below 1%, no repeat dimensional defect

Monthly

Weld rework and grinding hours per assembly

Reduction of 30%

Monthly

Fixture project delivery - concept to commissioned

On or before committed date, 90% adherence

Per project

Weld map and WPS coverage of running assemblies

100% of A and B class assemblies documented

Quarterly

Changeover time between variants on family fixtures

Single-digit minutes

Per project

Tooling cost against approved budget

Within budget cost-down on repeat fixtures

Quarterly

Safety and 5S compliance in tool room and fixture area

Zero incidents, audit score above 90%

Monthly

6. Preferred Source Companies (Tier-1 Talent Pools)

The strongest candidates for this role do not come from design-office-only backgrounds. They come from organisations where fixture design sits inside the plant and the designer is accountable for the tool working on the line. The lists below are ordered by fit. Band A should be the primary search target Band B and Band C are valid secondary pools.

Band A - Highest preference: welded structure, enclosure and chassis fabrication with a mature fixture culture

Segment

Companies to target

What the candidate brings

Auto chassis, BIW and welded assembly Tier-1s

JBM Group (JBM Auto, Neel Metal Products), Tata AutoComp Systems, Sandhar Technologies, Krishna Maruti, Jay Bharat Maruti, Mark Exhaust Systems, Bharat Seats, Caparo India, Sona Comstar, Endurance Technologies, Gabriel India, Wheels India, Sundram Fasteners, Rane Group, Brakes India, Lucas-TVS, Sundaram Clayton, Motherson (SMP / SMR), Faurecia, Benteler, Magna Automotive India, Tower Automotive

Highest fixture discipline in the country - 3-2-1 and RPS locating, tolerance stack-up, PFMEA-linked tooling, launch discipline under IATF 16949

Electrical enclosures, switchgear and cabinet fabrication

Rittal India, Schneider Electric, ABB India, Hitachi Energy, Siemens, Eaton, Legrand, nVent, C&S; Electric, Delta Electronics India, Salzer Electronics, Pentair

Directly relevant to enclosure, cabinet and energy-storage structures - thin-sheet weld distortion control, cosmetic weld quality, high-mix variant families

Heavy fabrication, off-highway and construction equipment

Caterpillar India, Komatsu India, JCB India, Tata Hitachi, L&T; Construction Equipment, Volvo CE / Volvo Group India, Terex, Escorts Kubota, BEML, Sany India, Ashok Leyland, Daimler India Commercial Vehicles, VE Commercial Vehicles

Large weldment fixturing, heavy structural welding, camber and distortion management, AWS D1.1 environment

Railway, coach and rolling stock fabrication

Alstom Transport (including Sri City), Titagarh Rail Systems, Wabtec (Hosur), Medha Servo Drives, Siemens Mobility, ICF / RCF ancillary fabricators

Long-length weldment fixturing, weld mapping and weld traceability, EN 15085 / ISO 3834 documentation habits

Prepared by Manufacturing Excellence . For internal recruitment use . Revision 01

📌 Deputy Engineer (India)
🏢 Amara Raja Group
📍 India