The Tool Designer is responsible for the end-to-end design and delivery of lifting handling and assembly tools for hydro turbine and generator components. This role spans concept development 3D modeling detailed drawings engineering calculations and technical support through manufacturing testing and field use. The lead will guide a small team of designers/engineers ensure compliance with applicable standards and drive design quality safety and cost effectiveness.
Job Description
Key Responsibilities
1. Concept Development & Engineering
- Develop tool concepts for lifting handling assembly and maintenance of hydro turbine and generator components (e.g. runner shaft rotor stator poles covers etc.).
- Analyze customer / project requirements site constraints and interface data to define tool functional requirements and boundary conditions.
- Prepare concept layouts sketches and simplified models to evaluate feasibility ergonomics and safety.
- Lead technical reviews to compare design alternatives for safety manufacturability cost and schedule impact.
- Coordinate with installation service manufacturing and project teams to validate concepts and collect feedback.
2. 3D Modeling & Digital Mock-Up
- Creation of accurate 3D models of lifting and handling tools using e.g. NX / Creo / SolidWorks / Inventor / CATIA customize as needed.
- Integrate tools into turbine/generator 3D assemblies to verify clearances interfaces and handling sequences (DMU checks).
- Manage parametric models to allow reuse and customization of existing tool designs.
- Maintain CAD standards model quality naming conventions and data structure in the PLM system.
3. Detail Drawing & Documentation
- Generate and review manufacturing drawings for components and assemblies including:
- Dimensions tolerances (GD&T; as relevant)
- Welding details machining notes and surface treatments
- Bill of Materials (BOM)
- Assembly and installation drawings
- Ensure drawings comply with internal standards and relevant international standards (e.g. ISO ASME DIN EN).
- Prepare user documentation (e.g. operating instructions lifting plans inspection and maintenance guidelines) in collaboration with HSE and field teams.
4. Engineering Calculations & Verification
- Perform structural calculations for lifting and handling tools including:
- Static strength and stiffness
- Local stresses in critical areas (lifting lugs welds pins hooks etc.)
- Stability checks (center of gravity tipping overturning)
- Fatigue assessment where applicable
- Apply relevant design codes and standards for lifting equipment and below-the-hook devices (e.g. EN 13155 ASME B30/BTH local regulations adjust to your context).
- Use hand calculations and/or CAE tools (e.g. FEA) to validate design integrity and safety factors.
- Support risk assessments (FMEA hazard analysis etc.) for special tools.
5. Project & Team Leadership
- Plan and prioritize tool design activities according to project schedules and resource availability.
- Be a team player providing technical guidance and on-the-job training.
- Report the progress and ensure timely delivery of design packages (concepts models drawings calculations).
- Conduct design reviews and ensure that design decisions are documented and communicated.
- Collaborate with procurement suppliers manufacturing and quality to resolve technical issues and optimize designs for fabrication and assembly.
- Drive continuous improvement in design methods standards and reusable design solutions.
6. Interface Management & Support
- Serve as the primary technical contact for special tools within projects (internal and external stakeholders).
- Support manufacturing assembly and site teams during tool fabrication testing and first-time use.
- Participate in troubleshooting and root-cause analysis for any issues in the field proposing design improvements.
- Contribute to standardization of recurring tools and tool families for turbines and generators.
Required Qualifications
- Bachelors degree in Mechanical Engineering Design Engineering or related field.
(Masters degree is a plus.)
- 5 years of experience in mechanical design including:
- Significant experience with lifting handling or assembly tooling preferably for large rotating machines heavy equipment or power generation.
- Robust proficiency in at least one major 3D CAD system (e.g. NX Creo SolidWorks Inventor CATIA).
- Solid experience in preparing detailed manufacturing drawings including GD&T; and BOMs.
- Demonstrated capability in performing and documenting engineering calculations for structural components (hand calculations and/or FEA).
- Familiarity with codes and standards relevant to lifting devices and mechanical structures (e.g. EN 13155 ASME standards Eurocodes or similar adapt to your region).
- Experience working within a PLM system (e.g. Teamcenter Windchill SAP PLM etc.) is an advantage.
- Ability to translate functional requirements into robust practical mechanical designs.
- Analytical mindset with attention to detail and a strong focus on safety and reliability.
- Effective communication skills: capable of explaining technical topics to non-specialists (project managers site teams suppliers).
- Leadership and mentoring ability; comfortable guiding less-experienced engineers/designers.
- Proactive solution-oriented able to work independently and in cross-functional teams.
- Fluent in English / local language; additional languages are a plus for global projects.
Preferred / Nice-to-Have
- Experience in hydro power equipment (turbines generators) or large rotating machinery.
- Knowledge of rigging plans lifting studies and collaboration with crane vendors.
- Hands-on exposure to site installation or service activities.
- Experience with FEA tools (e.g. ANSYS Abaqus Nastran) for structural analysis.
- Exposure to risk assessment methods (FMEA HAZOP etc.).
- Previous experience in a lead or senior design role.
Performance Indicators
- Quality and safety of delivered tool designs (no failures or major rework in field use).
- On-time delivery of design packages relative to project milestones.
- Compliance with standards and internal design rules.
- Level of standardization and reuse of tools across projects.
- Team development and effective knowledge sharing.
Additional Information
Relocation Assistance Provided: Yes
Required Experience:
IC
📌 Engineer Tooling (Vadodara)
🏢 GE Vernova
📍 Vadodara
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