Engineering Lead - DFM

Larsen & Toubro; Bengaluru; On-site; INR 3,000,000 - 5,000,000; Full time

Benefits offered by this job

Job summary

Larsen & Toubro (L&T) invites an experienced DFM Leader - Motor to own end-to-end design and industrialization of traction motors for EV platforms. You will lead architecture, design reviews, and cross-functional alignment with manufacturing, supply chain and quality teams.

You will drive DFMEA/PFMEA, APQP/PPAP, and supplier development, ensuring robust, scalable motor platforms while upholding safety and regulatory standards across ISO 9001/16949, ISO 26262 and related norms.

Qualifications

• Bachelor’s or Master’s degree in Electrical, Electronics or Computer Science Engineering.
• 12+ years of experience in electric motor design/manufacturing, with at least 5 years in a senior leadership position within a Tier-1 supplier/OEM.
• Proven track record taking traction motors from concept to mass production at automotive scale.
• Strong DFM/DFA expertise focusing on laminations, winding, machining, balancing, sealing and EOL testing.
• Fluency in DFMEA/PFMEA, Control Plans, APQP/PPAP.
• Quality and Safety Systems: IATF 16949/ISO 26262, VDA 6.3, IEC 60034, UL/CE, RoHS/REACH.

Responsibilities

• Own end-to-end design and industrialization of traction motors and sub-systems.
• Lead product architecture across multiple vehicle platforms (power, torque, efficiency, NVH, durability, thermal, packaging).
• Drive concept-to-launch lifecycle including requirements, CAD/CAE, prototyping, V&V, DV/PV and ramp to mass production.
• Establish design standards, reviews, configuration control, and PLM governance.
• Champion modularity and platform reuse to reduce complexity and cost.
• Translate requirements into manufacture-ready designs including lamination stacking, winding, impregnation, rotor assembly, shaft, housing and end-cap design.
• Define end-of-line test strategy and validation plans.
• Partner with plant leadership to define line layouts, automation, tooling and test equipment.
• Embed Lean and Six Sigma, drive kaizen and continuous improvement.
• Qualify and develop suppliers; manage APQP, PPAP and VDA 6.3 audits.

Skills

Design Leadership

Product Architecture

DFM/DFA

APQP/PPAP

PLM Governance

Lean & Six Sigma

Supplier Development

Quality & Safety

Stakeholder Management

Program Management

Education

Bachelor’s or Master’s in Electrical Engineering

Electronics or Computer Science

Tools

CAD

CAЕ

PLM

Finite Element Analysis

Job description

Business Unit: EPS Mobility
Role: DFM Leader - Motor

We are seeking a seasoned engineering leader to own end ? to ? end design and industrialization of traction motors and related sub-systems (e.g., rotor/stator stacks, housings, shafts, bearings, cooling systems, encapsulation, sensors). This role combines deep product design expertise with manufacturing, supply chain, operations, quality, and safety leadership to deliver robust, cost ? effective, and scalable EV motor platforms.

Key Responsibilities

• Design Leadership & Product Architecture
• Own the product architecture for traction motors across multiple vehicle platforms (power, torque, efficiency, NVH, durability, thermal, packaging).
• Drive concept-to-launch lifecycle: requirements, system architecture, trade studies, CAD, CAE, prototyping, V&V, DV/PV, and ramp to mass production.
• Establish and enforce design standards, design reviews, configuration control, and PLM governance.
• Champion modularity and platform reuse to reduce complexity, cost, and time-to-market.
• DFM/DFA & Industrialization
• Translate product requirements into manufacture-ready designs: lamination stacking, stator winding (hairpin, distributed, concentrated), impregnation/varnishing, rotor assembly (IPM/SPM), shaft design, balancing, housing and end-cap machining, sealing, and potting.
• Optimize tolerances and GD&T for manufacturability; conduct DFM/DFA workshops with suppliers and plant engineers.
• Implement DFMEA/PFMEA, Control Plans, and Process Capability (Cp/Cpk) targets; drive APQP deliverables and PPAP approval.
• Define end-of-line test strategy (electrical performance, insulation, partial discharge, vibration, noise, thermal run, dimensional checks).
• Operations Interface & Ramp Readiness
• Partner with plant leadership to define line layouts, automation needs (winding, insertion, forming, welding, impregnation, assembly), tooling/fixtures, and test equipment.
• Ensure process validation (IQ/OQ/PQ), first-pass yield, takt time alignment, OEE, and throughput targets.
• Embed Lean and Six Sigma principles—error-proofing (Poka?Yoke), standardized work, and continuous improvement (Kaizen).
• Supply Chain & Supplier Development
• Co-lead make/buy strategy, should-cost modeling, and value engineering (VAVE).
• Qualify and develop suppliers for laminations, copper, magnets (NdFeB), die castings, machined parts, insulation systems, adhesives, and sensors.
• Drive supplier APQP, PPAP, VDA 6.3 audits, incoming quality planning, and dual-sourcing/risk mitigation.
• Negotiate engineering changes, lifecycle cost reduction, and long-lead material risk (magnets/copper).
• Quality, Safety & Compliance
• Own product quality targets (PPM, warranty, reliability, durability) and 8D/root cause culture.
• Ensure compliance with IATF 16949 / ISO 9001, ISO 26262 (ASIL where applicable), IEC 60034 family, UL/CE where relevant, RoHS/REACH, HV safety, and EHS requirements.
• Lead cross-functional change control (ECN/ECO) with robust verification/validation and traceability.

Qualifications

• Bachelor’s or Master’s degree in Electrical, Electronics or Computer Science Engineering.
• 12+ years of experience in electric motor design/manufacturing, with at least 5 years in a senior leadership position within a Tier-1 supplier/OEM.
• Proven track record taking tractoin motors from concept to mass production at automotive scale
• Strong DFM/DFA expertise: laminations, stamping, stacking, hairpin/conventional winding, welding (laser/TIG), machining, balancing, sealing and EOL testing
• Fluency in DFMEA/PFMEA, Control Plans, APQP/PPAP
• Quality and Safety Systems: IATF 16949/ISO 26262, VDA 6.3, basic IEC 60034 understanding, UL/CE, RoHS/REACH, HV safety practices
• Demonstrated leadership with suppliers and operations: Costing, acquisitions, VAVE, dual sourcing, launch ramp
• Excellent communication, stakeholder management and decision making under ambiguity

L&T Company Overview / About Us

L&T is a USD 30 billion Indian multinational engaged in EPC Projects, Hi-Tech Manufacturing, and Services, operating across multiple geographies. A strong, customer–focussed approach and the constant quest for top-class quality have enabled L&T to attain and sustain leadership in its major lines of business for eight decades.

Given L&T’s capability in strategic electronics and leveraging its foray into semiconductor design and well-established capabilities in L&T Technology Services, the business is expanding its offerings to cover industrial electronic modules, products and systems in critical sectors of Power Electronics, Automotive Electronics, Industrial Robotics & Automation, Communication Platforms and Electronic Systems Design & Manufacturing (ESDM). The focus products under Automotive Electronics are ADAS, Electrification & Connectivity related products.