Engineering Manager (NPD)

Saaki Argus And Averil Consulting; Chennai; On-site; INR 1,200,000 - 1,900,000; Full time

Job summary

Saaki Argus And Averil Consulting seeks a senior Manufacturing Engineer specializing in gear, spline, and shaft production. You will review drawings and standards, develop process plans and tooling, and drive APQP, PFMEA, and PPAP activities for international OEM projects.

Responsibilities include selecting CNC machinery, validating processes, and coordinating line setups. You will mentor teams and ensure smooth handover to mass production while maintaining quality and reliability.

Qualifications

• 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.
• Strong technical problem-solving, project execution, and communication skills.

Responsibilities

• Review customer drawings, GD&T, material specifications, and international standards.
• 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.
• Develop tooling plans for cutting tools, fixtures, gauging, and master gears.
• Evaluate material selection, forging processes, heat treatment, and distortion impact.
• Lead APQP phases and ensure timely NPD milestones.
• Coordinate dimensional inspection, material validation, and metallurgical testing.
• Lead PPAP preparation and customer approvals before production release.
• Establish SPC practices and inspection methods using CMM and gear testers.
• Evaluate CNC machines, tooling, and program optimization across controls.
• Lead machine prove-outs, line commissioning, and cycle-time optimization.
• Identify automation opportunities including robotics and gantry systems.
• Design manufacturing layouts and balance lines for new product lines.

Skills

Gear manufacturing

Spline manufacturing

Shaft manufacturing

CNC machining

APQP/PPAP

PFMEA

Process optimization

Project management

Cross-functional leadership

Tools

FANUC control systems

Siemens control systems

Mitsubishi control systems

Heidenhain control systems

Job description

Key Roles & Responsibilities1. Product & Process EngineeringReview 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 PlanningLead 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 EngineeringEvaluate 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 SetupDesign 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 CoordinationIndependently 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 HandoverLead 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 & CompetenciesExtensive 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.Strong technical problem-solving, project execution, and communication skills.