Manufacturing Engineer - Powertrain Machining

Ford; Chennai District; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Ford in Chennai seeks a seasoned Manufacturing Engineer to design and implement world-class CNC machining processes for powertrain programs. You will drive process flows, tooling layouts, SOPs, and production concepts while supporting launches and cost objectives.

You will work with global teams and suppliers to ensure process capability, PFMEA, and control plans meet safety and quality targets, with strong CAD and simulation proficiency essential.

Qualifications

• Bachelor's degree required in mechanical/automotive/manufacturing engineering or related field.
• 6+ years of manufacturing engineering experience in powertrain machining environments.
• Experience with CNC machining processes and prismatic component manufacturing.
• Knowledge of PFMEA, Control Plans, GD&T andProcess Capability Analysis.
• Experience with equipment automation, sourcing, installation and commissioning.

Responsibilities

• Develop and optimise manufacturing process flows, line layouts, and production concepts for prismatic machining programs.
• Prepare process sheets, tooling layouts, work instructions, and SOPs.
• Support new model launches, engineering changes, and process modifications.
• Simulate and validate machining processes before production.
• Collaborate with design teams to incorporate DFM early in development.

Skills

CNC machining

Prismatic component manufacturing

Cylinder block machining

Cylinder head machining

Automation systems

Machining equipment

CATIA

AutoCAD

Machining simulation tools

PFMEA

Control Plans

GD&T

Process capability analysis

Root cause analysis

Education

Bachelor's Degree in Mechanical Engineering, Automobile Engineering, Manufacturing Engineering, or related discipline

Tools

CATIA

AutoCAD

Job description

This role requires deep expertise in CNC machining, cutting tool technologies, automation systems, and manufacturing process capability. The successful candidate will be responsible for developing and implementing world-class machining processes that support quality, cost, safety, and productivity objectives across powertrain manufacturing programs.

You will collaborate with global teams, product engineering, suppliers, and plant operations to deliver robust manufacturing solutions while supporting future product launches and operational excellence initiatives.

Process Design & Development

• Develop and optimise manufacturing process flows, line layouts, and production concepts for new and existing prismatic machining programs in alignment with Bill of Process (BoP) standards.
• Prepare process sheets, tooling layouts, work instructions, and Standard Operating Procedures (SOPs).
• Support new model launches, engineering changes, and process modifications.
• Simulate and validate machining processes before production implementation.
• Collaborate with product design teams to ensure Design for Manufacturing (DFM) requirements are incorporated early in development.

Equipment & Tooling

• Define specifications and requirements for machining equipment, automation systems, fixtures, tooling, and gauging.
• Lead equipment sourcing, supplier technical reviews, installation, runoff, commissioning, and capability validation.
• Ensure equipment designs meet safety, ergonomic, quality, and production requirements.
• Apply expertise in superfinishing operations, including honing processes.

Quality & Continuous Improvement

• Conduct root cause analysis and implement corrective actions for manufacturing and quality concerns.
• Lead and support Process Failure Mode and Effects Analysis (PFMEA), Control Plans, Statistical Process Control (SPC), and poka-yoke initiatives.
• Drive Lean Manufacturing, Six Sigma, and Kaizen projects to improve productivity, quality, and cost performance.
• Improve process capability and reduce variation through systematic problem-solving methodologies.

Production Capacity & Cost Planning

• Support capital investment planning, cost estimation, and budget management activities.
• Perform capacity studies, line balancing, and takt-time analysis to support production volume requirements.
• Identify and implement cost reduction and productivity improvement opportunities.

Supplier & Procurement Management

• Develop Statements of Work (SOW) and Requests for Quotation (RFQ) packages for equipment and tooling suppliers.
• Evaluate supplier proposals for technical compliance, delivery, quality, and cost competitiveness.
• Support technical negotiations and procurement approval processes in accordance with company policies.
• Manage supplier deliverables throughout project execution and equipment commissioning.

OEM Documentation Management

• Ensure timely collection and validation of OEM documentation, including:
  • Reliability and Maintainability (R&M) reports
  • Spare parts lists
  • Equipment manuals
  • Installation drawings
  • Preventive Maintenance (PM) plans
• Coordinate with suppliers to resolve documentation gaps before project closure.

Safety & Compliance

• Ensure manufacturing systems comply with all applicable safety, environmental, and regulatory requirements.
• Conduct risk assessments and implement corrective actions to improve workplace safety.
• Support safety reviews during equipment design, installation, and launch phases.

Required Qualifications

• Bachelor''s Degree in Mechanical Engineering, Automobile Engineering, Manufacturing Engineering, or related discipline.
• 6+ years of manufacturing engineering experience, preferably within powertrain machining environments.
• Strong experience with:
  • CNC machining processes
  • Prismatic component manufacturing
  • Cylinder Block and Cylinder Head machining
  • Automation systems and manufacturing equipment
• Experience in manufacturing process development, installation, commissioning, and production launch activities.
• Proficiency in CATIA, AutoCAD, or equivalent CAD software.
• Experience using machining simulation and process validation tools.
• Strong knowledge of:
  • PFMEA
  • Control Plans
  • GD&T
  • Process Capability Analysis
  • Root Cause Analysis

Preferred Qualifications

• Experience with honing and superfinishing processes.
• Working knowledge of Lean Manufacturing, Six Sigma, and Kaizen methodologies.
• Experience managing capital equipment projects and supplier relationships.
• Exposure to global manufacturing operations and cross-functional collaboration.
• New model launch and program management experience.
• Familiarity with AI-assisted productivity tools and digital manufacturing initiatives.

Soft Skills

• Strong communication and stakeholder management skills.
• Ability to collaborate effectively with global teams.
• Strong presentation and influencing capabilities.
• Analytical thinking and structured problem-solving approach.
• Collaborative team player with a continuous improvement mindset.

Additional Requirement

• Willingness to travel globally and relocate temporarily or permanently to Ford manufacturing locations based on business and project requirements.