Manager Facilities Engineer

Caterpillar Inc.; Beed; On-site; INR 3,800,000 - 6,500,000; Full time

Job summary

Caterpillar Inc. is seeking an experienced Manufacturing Engineering Manager for Engine & Genset test operations in India. You will lead testing engineering, drive process improvements, and implement digital manufacturing across new and existing test facilities.

The role emphasizes NPI, CAPEX projects, safety, and cost optimization, with oversight of test automation, data systems, and regulatory compliance. Strong leadership and Six Sigma credentials are essential.

Qualifications

• Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Industrial Engineering, or Production Engineering.
• Lean Six Sigma Green Belt / Black Belt Certification.
• 18-20 years of Manufacturing Engineering experience.

Responsibilities

• Lead Engine and Genset Test Manufacturing Engineering activities across the facility.
• Develop manufacturing engineering strategies aligned with business objectives.
• Establish engineering standards, testing specifications, and best practices.
• Support production growth through capacity planning and technology deployment.
• Drive operational excellence through process optimization and innovation.
• Build a high-performance engineering organization focused on continuous improvement.
• Lead test process development for new engine and genset products.
• Lead safety, regulatory compliance, and risk assessments for fuel systems and high-voltage equipment.

Skills

Team leadership

Problem solving

Data analysis

Education

Bachelor's Degree in Mechanical Engineering

Tools

PLC Systems (Siemens, Rockwell)

SCADA Systems

DAQ Systems

HMI Systems

Industrial Networking

Industry 4.0 Applications

Job description

Career Area

Manufacturing

Job Description

When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other. We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it.

The Engine & Genset Test Manufacturing Engineering Manager is responsible for leading the manufacturing engineering, process development, automation, test technology, capital projects, and continuous improvement functions for engine and generator set testing operations. The role ensures robust, efficient, and reliable testing processes that support production, new product introduction, quality compliance, capacity expansion, and operational excellence.

This position drives engineering solutions for engine hot testing, genset load testing, emissions measurement, data acquisition systems, automation, and test facility modernization while optimizing safety, quality, delivery, and cost performance.

Key Responsibilities

• Lead Engine and Genset Test Manufacturing Engineering activities across the facility.
• Develop manufacturing engineering strategies aligned with business objectives.
• Establish engineering standards, testing specifications, and best practices.
• Support production growth through capacity planning and technology deployment.
• Drive operational excellence through process optimization and innovation.
• Build a high-performance engineering organization focused on continuous improvement.

Engine & Genset Test Process Engineering

Develop, Optimize, And Standardize

Engine Test Processes

• Hot test operations
• Engine performance verification
• Fuel consumption measurement
• Emissions testing
• End-of-line testing
• Functional validation
• Durability testing processes
• Troubleshooting and diagnostic processes

Genset Test Processes

• Load testing procedures
• Electrical performance testing
• Frequency and voltage regulation testing
• Noise and vibration testing
• Reliability validation testing
• Customer acceptance testing
• Final inspection and release testing

Key Deliverables

• Improved throughput and productivity
• Reduced test cycle time
• Enhanced first-pass yield
• Improved equipment utilization
• Standardized testing methodology
• Reduced quality defects and rework

Test Automation & Digital Manufacturing

Lead Development And Implementation Of

• Automated test systems -PUMA
• PLC-based test controls
• SCADA systems
• Data acquisition systems (DAQ)
• Engine control integration
• Genset controller integration
• Digital manufacturing solutions
• Real-time monitoring systems
• IIoT and Industry 4.0 applications
• Manufacturing analytics dashboards

Responsibilities

• Establish automated testing standards.
• Improve test data accuracy and traceability.
• Develop smart manufacturing solutions.
• Drive paperless operations and digital workflows.
• Support factory connectivity and data analytics initiatives.

Test Equipment & Facility Engineering

Responsible For Engineering And Optimization Of

• Engine dynamometers
• Hydraulic dynamometer systems
• Resistive and reactive load banks
• Fuel systems
• Cooling systems
• Air intake systems
• Exhaust extraction systems
• Emissions measurement systems
• Electrical distribution systems
• High-voltage testing infrastructure
• Instrumentation and sensors
• Calibration systems

Objectives

• Increase equipment capability.
• Improve test cell utilization.
• Optimize facility layout and workflow.
• Enhance reliability and maintainability.

New Product Introduction (NPI) & Industrialization

• Lead test process development for new engine and genset products.
• Support APQP and product launch activities.
• Develop Process Flow Diagrams (PFDs).
• Create PFMEA and Control Plans.
• Conduct process validation and capability studies.
• Support pilot builds and production trials.
• Ensure smooth product launches with minimal disruption.

Capital Projects & Capacity Expansion

• Lead planning and execution of capital investment projects.
• Develop CAPEX business cases.
• Define technical specifications for new test equipment.
• Manage supplier selection and technical evaluations.
• Coordinate installation and commissioning activities.
• Deliver projects on schedule and within budget.

Typical Projects

• New engine test cells
• New genset test bays
• Load bank installations
• Emissions laboratories
• Automated testing systems
• Industry 4.0 implementation
• Capacity expansion programs
• Facility modernization initiatives

Continuous Improvement & Operational Excellence

• Drive Lean Manufacturing and Six Sigma initiatives.
• Improve Overall Equipment Effectiveness (OEE).
• Reduce testing costs and cycle times.
• Improve First Pass Yield (FPY).
• Lead Value Stream Mapping activities.
• Conduct Kaizen workshops.
• Implement best practices across manufacturing operations.

Quality Engineering Support

• Establish robust process controls for testing operations.
• Analyze quality and test failure trends.
• Lead root cause investigations.
• Implement corrective and preventive actions.
• Support customer audits and regulatory compliance audits.
• Improve test accuracy and repeatability.

Focus Areas

• Test repeatability
• Data integrity
• Process capability
• Defect prevention
• Warranty reduction
• Customer satisfaction

Safety & Regulatory Compliance

• Ensure compliance with all EHS and plant safety requirements.
• Lead risk assessments for fuel systems, rotating machinery, and high-voltage equipment.
• Develop safe testing procedures and standards.
• Support ISO 14001, ISO 45001 requirements.
• Ensure compliance with emissions and customer-specific testing regulations.
• Promote a zero-incident safety culture.

Team Leadership & Talent Development

• Lead a team of Manufacturing Engineers, Process Engineers, Automation Engineers, and Project Engineers.
• Develop technical competency in engine and genset testing technologies.
• Establish succession planning and career development programs.
• Mentor engineers in testing methodologies and manufacturing excellence.
• Foster innovation, accountability, and continuous learning.

Required

Educational Qualifications

• Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Industrial Engineering, or Production Engineering.

Preferred

• Lean Six Sigma Green Belt / Black Belt Certification.
• Project Management Certification (PMP).
• Industry 4.0 or Automation Certifications.

Experience

Required

• 18-20 years of Manufacturing Engineering experience.
• Strong experience in engine, powertrain, genset, automotive, or industrial equipment testing operations.

Preferred

• Experience with engine dynamometers and genset test facilities.
• New Product Introduction (NPI) experience.
• Greenfield plant development and commissioning.
• Exposure to digital manufacturing and test automation systems.

Technical Competencies

Engine & Genset Testing

• Engine Performance Testing
• Dynamometer Systems
• Genset Load Testing
• Emissions Testing
• Fuel System Analysis
• Electrical Performance Testing

Manufacturing Engineering

• APQP
• PFMEA
• Process Validation
• Capacity Planning
• Line Balancing
• Industrial Engineering

Automation & Controls

• PLC Systems (Siemens, Rockwell)
• SCADA Systems
• DAQ Systems
• HMI Systems
• Industrial Networking
• Industry 4.0 Applications

Continuous Improvement

• Lean Manufacturing
• Six Sigma
• TPM
• OEE
• Root Cause Analysis
• Kaizen
• Value Stream Mapping

Project Management

• CAPEX Management
• Facility Expansion
• Equipment Procurement