Research Engineering Professional

Blue Star; Tirupati; On-site; INR 1,500,000 - 2,200,000; Full time

Job summary

Blue Star invites an experienced NPD Projects System Integrator (Room AC) to lead end-to-end design integration from concept to mass production of RAC platforms, including Window/Split units.

You will drive DFMEA, DFM/DFA, prototyping, lab testing coordination, part development support, and pilot trials on the manufacturing line, ensuring quality and schedule.

Qualifications

• Experience in NPD system integration for RAC or HVAC products.
• Ability to apply DFM/ DFA early in design to avoid bottlenecks.
• Exposure to DFMEA sessions with risk mitigation.
• Experience supervising mockups and proto builds with cross-functional teams.
• Strong project scheduling and cross-functional collaboration.

Responsibilities

• Lead end-to-end NPD System Integration for Room AC units (Window/Split), ensuring structural integrity, airflow and aesthetics; apply DFM and DFA to minimize bottlenecks; lead DFMEA sessions for risk mitigation.
• Supervise fabrication of mockups and engineering prototypes; coordinate Proto CFT inspections and assembly trials; document and track issues for root-cause analysis.
• Schedule and oversee Psychrometric Lab Testing; analyze data against specs and troubleshoot performance gaps.
• Support sourcing in New Part Development; provide technical clarity to vendors for plastics, sheet metal and outsourced components; assist QA to ensure part-readiness for QA clearance.
• Plan and manage Pilot Trials on the manufacturing line; maintain project schedules and drive on-time tooling kickoff.

Skills

NPD system integration

DFMEA leadership

DFM/DFA application

Prototyping supervision

Project scheduling

Job description

Job Description

The NPD Projects System Integrator (Room AC) will be responsible for leading the end-to-end design integration, prototyping, testing, and transition of new Room Air Conditioner (RAC) platforms from concept to mass production.

• New Product Development (NPD) System IntegrationOwn the system integration of Room AC units (Window/Split), ensuring structural integrity, optimal airflow, and aesthetic alignment.Apply DFM (Design for Manufacturing) and DFA (Design for Assembly) principles during the early design stages to minimize production bottlenecks.Lead and execute DFMEA (Design Failure Mode and Effects Analysis) sessions to identify risk, implement mitigation plans, and capture lessons learned.


• Mockup, Prototyping CFT InspectionSupervise the fabrication of mockups and engineering prototypes for physical verification.Coordinate Proto CFT (Cross-Functional Team) Inspections and assembly trials to evaluate fitment, component clearances, and harness routing.Document and track prototype build issues, driving root-cause analysis for any interference or assembly deviations.


• Psychrometric Lab Testing ValidationCollaborate with the performance team to schedule and oversee Psychrometric Lab Testing (Capacity, EER/ISEER, Max Operating Conditions).Analyze test data against target specifications and troubleshoot system-level performance gaps (e.g., airflow bypass, sweat/condensate issues).


• New Part Development Quality SupportSupport the sourcing team in New Part Development, providing technical clarity to vendors for plastics, sheet metal, and outsourced electrical components.Assist Quality Assurance (QA) in component verification, ensuring part-readiness for QA Clearance Support prior to pilot builds.


• Pilot Trials Project ExecutionDevelop and manage comprehensive Project Scheduling timelines using Gantt charts or project management software to ensure critical milestones are met.Lead Pilot Trial Execution on the manufacturing line, monitoring first-run assembly processes.Own the Pilot Lot Observation Closure process, ensuring all assembly, quality, and performance snags are resolved before final tooling kickoff.