Process & Tool Design Engineer -Wind Turbine Gearbox

Pioneer Filmed; Pune District; On-site; INR 1,200,000 - 2,400,000; Full time

Job summary

Pioneer Filmed is seeking a Process & Tool Design Engineer for wind turbine gearboxes in Pune. You will standardize assembly workflows, author SOPs, and develop specialized tooling for high-torque joints and heavy components.

Responsibilities include designing heavy-duty fixtures, planning plant layouts, conducting PFMEA, and validating tooling with FEA. Ideal candidates hold a mechanical engineering degree and 4–8 years in gear assembly environments.

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 4–8 years in process planning and tool design in heavy machinery.
• Proficient CAD/CAE and GD&T knowledge.

Responsibilities

• Standardize assembly workflows and create specialized tooling.
• Design heavy-duty fixtures and lifting rigs for multi-ton components.
• Lead risk assessments and implement corrective actions.
• Ensure safety, quality, and ISO 9001 compliance.

Skills

Heavy equipment safety

Cross-functional collaboration

Project coordination

Troubleshooting

Education

Bachelor's degree in Mechanical Engineering

Experience in tool design or process planning

Tools

SolidWorks

Creo

CATIA

Job description

Dear Candidate,

Job Title: Process & Tool Design Engineer (Wind Turbine Gearbox), Pune Location.

Job Purpose

The Process & Tool Design Engineer standardizes assembly workflows and creates specialized mechanical tooling for multi-megawatt wind turbine gearboxes (WTG). This role ensures high-precision torque applications, safe handling of heavy multi-ton components, and flawless execution of complex interference fits. The engineer works to reduce assembly cycle time while maintaining strict safety, quality, and ISO 9001 standards.

Key Responsibilities

Assembly Process Engineering

• Develop Assembly Routing: Author detailed Standard Operating Procedures (SOPs), digital work instructions, and routing sheets for planetary, helical, and high-speed gear stages.
• Design Plant Layouts: Create and optimize floor layouts for assembly stations, heavy rigging, paint booths, and end-of-line test benches to minimize component travel.
• Manage Critical Joints: Define and control strict tightening processes for critical high-torque bolted joints, utilizing hydraulic tensioners and calibrated DC electric torque tools.
• Implement Thermal Assembly: Establish precise process controls for heating housings or induction-heating large bearings and gears to execute interference fits smoothly.

Tooling & Fixture Design

• Design Heavy-Duty Fixtures: Utilize 3D CAD software (SolidWorks, Creo, or CATIA) to develop robust assembly jigs, turnover fixtures, and alignment gear.
• Develop Lifting & Rigging Jigs: Engineer custom lifting beams, hooks, and shackle configurations for safely manoeuvring multi-ton castings, shafts, and completed gearboxes using EOT cranes.
• Conduct Tolerance Stack-Up: Perform comprehensive tolerance stack-up analyses and apply Geometric Dimensioning and Tolerancing (GD&T) to ensure precision tooling fitment.
• Validate & Test Tooling: Execute structural calculations, Finite Element Analysis (FEA), and physical load testing to certify tooling safety factors before shop floor deployment.

Continuous Improvement & Quality

• Lead Risk Assessments: Conduct Process Failure Mode and Effects Analysis (PFMEA) to identify and mitigate assembly risks proactively.
• Perform Root Cause Analysis: Investigate assembly line defects or field failures, implementing definitive corrective actions and engineering solutions.
• Drive Lean Initiatives: Shorten takt times and eliminate assembly waste using 5S, poka-yoke (mistake-proofing), and ergonomic design principles.

Key Performance Indicators (KPIs)

• First Time Right (FTR): Percentage of gearboxes successfully assembled and passing spin/load testing without rework.
• Tooling Lead Time: Meeting development and fabrication timelines for new or updated fixtures.
• Cycle Time Reduction: Decreasing the total hours required to assemble a single gearbox.
• Safety Incidents: Zero floor accidents related to lifting equipment or heavy fixture failures.

Qualifications & Experience

Education & Background

• Degree: Bachelor’s degree in Mechanical Engineering, Production Engineering, or Tool & Die Design.
• Experience: 4 to 8 years in process planning and tool design, explicitly within high-capacity industrial gearbox or heavy rotating equipment assembly plants.

Technical Competencies

• CAD/CAE Expertise: High proficiency in 3D modelling programs (e.g., SolidWorks, Inventor) and structural simulation software.
• Manufacturing Knowledge: Deep understanding of bearing fitments, gear tooth contact alignment, and heavy-component rigging safety.
• Tooling Fabrication: Practical knowledge of tool-room machinery, welding practices, and metal properties to manage vendor fabrications.

Soft Skills

• Safety First Mindset: Complete commitment to safety standards when designing rigs for heavy payloads.
• Cross-Functional Collaboration: Strong communication skills to act as the technical liaison between R&D, Quality, and Shop Floor Operators.