Manufacturing Engineering Engineer

Apollo Heat Exchangers; Boisar; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Apollo Heat Exchangers is seeking a skilled Process Development and Manufacturing Engineer to lead the refinement of aluminium heat exchanger production, welding assemblies, and automation integration. You will drive improvements in cycle times, waste reduction, and cost through Lean/Six Sigma methods while maintaining high-quality standards.

You will provide on-floor engineering support for vacuum brazing and welding, perform RCA for defects, collaborate with R&D, QA, and Maintenance, and

Qualifications

• Expertise in vacuum brazing furnace operation, TIG/MIG welding, and automation systems.
• Proficiency in CAD/CAM software (SolidWorks, Creo, AutoCAD) and manufacturing ERP/MES platforms.
• Strong analytical skills with experience in DVPR, PFMEA, and process validation.
• Certifications: Lean Six Sigma (Green/Black Belt).

Responsibilities

• Develop and refine manufacturing processes for aluminium heat exchangers and welding assemblies.
• Provide on-floor engineering support for vacuum brazing, welding, and assembly processes.
• Oversee operation, maintenance, and calibration of welding systems and automation equipment.
• Ensure adherence to standards (ASME, ISO, AWS) and support quality/performance improvements.
• Partner with R&D to transition prototypes to production and validate designs.
• Create and maintain process documentation and train production teams.
• Lead Lean/Six Sigma projects to reduce bottlenecks and improve productivity.
• Maintain health, safety, and environmental compliance in manufacturing.

Skills

Vacuum brazing

TIG welding

MIG welding

Automation systems

CAD/CAM software

SolidWorks

Creo

AutoCAD

ERP/MES platforms

DVPR

PFMEA

Process validation

Lean Six Sigma Green/Black Belt

Tools

Vacuum Brazing Furnaces

TIG welding systems

MIG welding systems

Automation equipment

Job description

Role & responsibilities

1. Process Development & Optimization:

   • Develop and refine manufacturing processes for aluminium heat exchangers and welding assemblies, utilizing TIG, MIG, other welding techniques.
   • Reduce cycle times, material waste, and costs while maintaining product quality & integrity. (Muda/Muri)
   • Identify cost-saving opportunities through process improvements and material optimization.

2. Technical Support & Troubleshooting:

   • Provide on-floor engineering support to resolve issues in vacuum brazing, welding, and assembly processes.
   • Conduct root cause analysis (RCA) for production defects, non-conformances, or equipment failures.
   • Collaborate with cross-functional teams (R&D, Quality, Maintenance) to implement corrective actions.
   • Workplace design / Current and future facility plant layout planning; reduce downtime (OEE), and liaise with cross-functional teams for seamless operations.

3. Equipment & Tooling Management:

   • Oversee the operation, maintenance, and calibration of vacuum brazing furnaces, TIG/MIG welding systems, and automation equipment.
   • Design or modify fixtures, jigs, and tooling to improve process repeatability and ergonomics and to enhance precision and efficiency.

4. Quality & Compliance:

   • Ensure adherence to industry standards (ASME, ISO, AWS) / EN ISO 3834-2, EN ISO 15085-2 CL1, ISO 9001, IATF 16949, OSHAS, ISO 14001 and Exposure to IRIS & AS 9100 D / NADCAP.
   • Develop inspection protocols, including non-destructive testing (NDT) for weld integrity and brazed joint quality.
   • Support APQP, PPAP, FMEA, and control plan development for new product launches.
   • Collaborate with QA teams to meet ISO/ASME standards, conduct root cause analysis, and implement corrective actions.

5. New Product Introduction (NPI):

   • Partner with R&D to transition prototypes to full-scale production, ensuring manufacturability and scalability.
   • Validate new designs through prototyping, process simulations, and testing (e.g., thermal performance, pressure cycles).

6. Documentation & Training:

   • Create and maintain detailed process documentation, including work instructions, standard operating procedures (SOPs), and process flow diagrams.
   • Train production teams on new equipment, processes, quality standards and safety protocols.

7. Continuous Improvement:

   • Lead Lean/Six Sigma projects to eliminate bottlenecks and enhance productivity.
   • Implement data-driven solutions using statistical analysis (SPC) and process monitoring tools.

8. Health, Safety, and Environmental Compliance:

   • Ensure all manufacturing processes comply with health, safety, and environmental regulations.
   • Promote a culture of safety and continuous improvement within the manufacturing team.

Preferred candidate profile

• Expertise in vacuum brazing furnace operation, TIG / MIG welding, and automation systems.
• Proficiency in CAD/CAM software (SolidWorks, Creo, AutoCAD) and manufacturing ERP/ MES platforms.
• Strong analytical skills with experience in DVPR, PFMEA, and process validation.
• Technical Skills:* Proficiency in CAD/CAM (SolidWorks, AutoCAD), aluminium metallurgy, welding standards (AWS), and quality tools (SPC, PFMEA).
• Certifications: Lean Six Sigma (Green/Black Belt).
• Soft Skills:* Strong problem-solving, communication, and project management abilities.