This role is a critical leadership position<\/b> responsible for driving industrialization, assembly excellence, and reliability engineering of aerospace\-grade motor assemblies and electro\-mechanical systems<\/b>.
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The candidate must demonstrate deep domain expertise in precision motor assembly, aerospace standards, complex mechanical systems, and NPI execution<\/b>, along with strong capability in team leadership, supplier collaboration, and customer\-facing problem resolution<\/b>.
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Core Responsibilities (Detailed & Interview\-Level Depth)<\/b>
<\/h1>1. Electro mechanical Assembly Expertise<\/b>
<\/h2>- Lead manufacturing and assembly of high\-precision aerospace motors<\/b> including:
- BLDC / AC / DC motors
<\/li> - Servo motors / actuators
<\/li> - High\-speed rotating systems
<\/li><\/ul><\/li> - Deep understanding of:
- Rotor\-stator assembly alignment<\/b>
<\/li>- Dynamic balancing (G\-level accuracy)<\/b>
<\/li>- Bearing selection, preload, lubrication techniques<\/b>
<\/li>- Winding processes, insulation systems, varnishing<\/b>
<\/li><\/ul><\/li>- Address critical parameters:
- Runout, concentricity, vibration limits
<\/li> - Thermal expansion & heat dissipation
<\/li> - Noise and performance stability
<\/li><\/ul><\/li> - Ensure compliance with aerospace tolerances and traceability requirements<\/b>
<\/li><\/ul>
2. Electro\-Mechanical Systems Integration<\/b>
<\/h2>- Manage full assembly lifecycle of electro\-mechanical products<\/b>, including:
- Motors + Controllers + Harnessing + Sensors
<\/li><\/ul><\/li> - Integration challenges:
- EMI/EMC considerations
<\/li> - Thermal and structural interactions
<\/li> - Precision fitment of mechanical + electrical interfaces
<\/li><\/ul><\/li> - Validate system\-level performance under:
- Vibration, shock, thermal cycling
<\/li> - Endurance / life\-cycle testing
<\/li><\/ul><\/li><\/ul>
3. Advanced NPI & Industrialization<\/b>
<\/h2>- Lead end\-to\-end aerospace NPI programs<\/b>:
- Design transfer → Proto → EVT / DVT / PVT → Mass production
<\/li><\/ul><\/li> - Drive:
- DFM / DFA optimization<\/b>
<\/li>- Manufacturing readiness reviews (MRR)
<\/li> - Risk mitigation plans (DFMEA / PFMEA)
<\/li><\/ul><\/li> - Establish:
- Process flow diagrams, control plans, work instructions<\/b>
<\/li><\/ul><\/li>- Ensure readiness for:
- AS9100 audit compliance
<\/li> - First\-time\-right production
<\/li><\/ul><\/li><\/ul>
4. Engineering Drawings & CAD Mastery<\/b>
<\/h2>- Expert\-level capability in CAD drawing reading and interpretation<\/b>:
- GD&T (ASME Y14.5 standard preferred)
<\/li> - Tolerance stack\-up analysis
<\/li> - Critical\-to\-function feature identification
<\/li><\/ul><\/li> - Ability to:
- Identify manufacturability risks directly from drawings
<\/li> - Suggest design corrections for assembly feasibility
<\/li><\/ul><\/li> - Work with tools:
- Creo / NX / SolidWorks
<\/li><\/ul><\/li> - Drive engineering change management (ECR/ECO)
<\/li><\/ul>
5. Tools, Jigs & Fixture Development (Critical Skill Area)<\/b>
<\/h2>- Design and validate:
- Assembly fixtures (alignment, press\-fit tools)<\/b>
<\/li>- Coil winding fixtures<\/b>
<\/li>- Rotor balancing setups<\/b>
<\/li><\/ul><\/li>- Knowledge of:
- Pneumatic / hydraulic tools
<\/li> - Torque control systems
<\/li> - Automated assembly stations
<\/li><\/ul><\/li> - Focus on:
- Error\-proofing (poka\-yoke)
<\/li> - Repeatability & precision
<\/li> - Cycle time reduction
<\/li><\/ul><\/li><\/ul>
6. FAIR, Quality & Aerospace Compliance<\/b>
<\/h2>- Lead FAIR (First Article Inspection Report)<\/b> execution as per AS9102<\/b>
<\/li>- Strong exposure to:
- AS9100, NADCAP (preferred)<\/b>
<\/li><\/ul><\/li>- Drive:
- APQP, PPAP (adapted for aerospace)
<\/li> - Control of special processes
<\/li><\/ul><\/li> - Perform:
- Root cause analysis (8D, Fishbone, 5 Why)
<\/li> - Failure investigations (fractography, wear analysis, misalignment)
<\/li><\/ul><\/li><\/ul>
7. Supplier Development & Field Problem Resolution<\/b>
<\/h2>- Extensive travel to supplier and customer locations<\/b> for:
- Process audits
<\/li> - Technical issue resolution
<\/li> - Qualification activities
<\/li><\/ul><\/li> - Manage:
- Supplier capability assessments
<\/li> - Critical component validation (laminations, bearings, shafts)
<\/li><\/ul><\/li> - Act as technical leader in:
- Customer escalations
<\/li> - On\-site troubleshooting of assembly failures
<\/li><\/ul><\/li><\/ul>
8. Team Leadership & Execution Excellence<\/b>
<\/h2>- Lead cross\-functional teams:
- Mechanical / Manufacturing / Quality engineers
<\/li><\/ul><\/li> - Drive:
- Performance management
<\/li> - Capability building (technical mentoring)
<\/li><\/ul><\/li> - Establish:
- Strong engineering governance
<\/li> - Structured problem\-solving culture
<\/li><\/ul><\/li><\/ul>
Required Qualifications<\/b>
<\/h1>- B.E / B.Tech / M.E in Mechanical Engineering<\/b>
<\/li>- 15\u201320 years in:
- Aerospace / defense / high\-reliability EMS
<\/li> - Motor assembly and electro\-mechanical systems
<\/li> - NPI and manufacturing engineering
<\/li><\/ul><\/li><\/ul>
Critical Technical Competencies <\/b>
<\/h1>- Aerospace motor assembly fundamentals
<\/li> - GD&T mastery & tolerance stack analysis
<\/li> - FAIR (AS9102), APQP, PPAP
<\/li> - Fixture/tooling design and validation
<\/li> - Failure analysis & reliability engineering
<\/li> - Supplier development and audits
<\/li> - Lean manufacturing & Six Sigma
<\/li><\/ul><\/div>
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