Sr. Engineer / Lead - NPD ME (Traction Motors)

Varroc; Chhatrapati Sambhajinagar District; On-site; INR 1,800,000 - 3,200,000; Full time

Job summary

Varroc is seeking a Manufacturing Engineering Lead and Sr. Engineers to design and execute manufacturing processes for traction motor products used in electric two- and three-wheelers. The team will own process flows, line layouts, tooling, and capacity planning across prototype to mass production.

You will lead NPD readiness, PFMEA, Control Plans, and Standard Work, while collaborating with R&D, Quality, and Production to ensure safe, high-quality, and cost-efficient launches.

Qualifications

• Experience in manufacturing engineering within automotive, EV or electromechanical product environments.
• Hands-on experience with NPD and production ramp-up activities.
• Proven experience in industrialization and manufacturing of electric traction motors, BLDC or PMSM.
• Strong understanding of motor manufacturing processes and assembly technologies.
• Familiarity with Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews.

Responsibilities

• Lead manufacturing engineering activities for traction motor products including stator, rotor, housing, shaft, magnet assembly, and final motor assembly.
• Develop and implement manufacturing strategies aligned with business growth and capacity requirements.
• Drive PFMEA, Process Flow Diagram, Control Plan, and Standard Work creation.

Skills

Electric motor manufacturing

Process engineering

Automation

Lean manufacturing

Project leadership

Education

Diploma / Bachelor's / Master's in mechanical engineering

Tools

Automation equipment development

MES systems

PFMEA

APQP/PPAP

Job description

We are seeking a highly motivated and experienced Manufacturing Engineering Lead and Sr. Engineers to drive manufacturing process design and execution for traction motor products used in electric 2-wheelers and 3-wheelers.

The role will be responsible for establishing robust manufacturing processes, leading industrialization activities, driving productivity improvements, and ensuring flawless launches of new motor programs from prototype through mass production.

The ideal candidate will possess deep expertise in electric motor manufacturing, process engineering, automation, assembly systems, quality improvement, and lean manufacturing principles.

Key Responsibilities:

• Lead manufacturing engineering activities for traction motor products including stator, rotor, housing, shaft, magnet assembly, and final motor assembly.
• Develop and implement manufacturing strategies aligned with business growth and capacity requirements.
• Support product development teams with Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews.
• Define manufacturing concepts, process flows, line layouts, equipment specifications, and capacity planning.

New Product Development (NPD)

• Analyze new RFQ for feasibility and estimate investment and process costing
• Drive manufacturing readiness for new product launches.
• Lead PFMEA, Process Flow Diagram, Control Plan, and Standard Work creation.
• Coordinate pilot builds, engineering builds, and production validation builds.
• Track and resolve manufacturing issues during ramp-up and SOP phases.

Process Engineering & Automation

• Identify and implement automation opportunities to improve quality, productivity, and safety.
• Define tooling, fixtures, poka-yoke solutions, and process controls.
• Drive OEE improvement, cycle time reduction, and yield enhancement initiatives.
• Lead Lean Manufacturing, Kaizen, Six Sigma, and cost optimization projects.
• Analyze manufacturing data and implement corrective and preventive actions.
• Establish best practices for process capability and operational excellence.
• Lead and mentor manufacturing engineers, technicians, and cross-functional teams.
• Collaborate closely with R&D, Quality, Supply Chain, Program Management, and Production teams.
• Drive a culture of safety, quality, innovation, and accountability.

Required Qualifications

• Diploma / Bachelor's / master's degree in mechanical engineering, Production Engineering, Electrical Engineering, Industrial Engineering, or related field.
• 5-15 years of experience in manufacturing engineering within automotive, EV, motor, or electromechanical product environments.
• Proven experience in industrialization and manufacturing of electric traction motors, BLDC motors, PMSM motors, or similar products.
• Hands-on experience with NPD and production ramp-up activities.
• Strong understanding of motor manufacturing processes and assembly technologies.

Preferred Technical Skills

• Stator winding technologies
• Rotor magnet assembly and balancing processes
• Motor testing systems
• Automation and manufacturing equipment development
• PFMEA, Control Plan, APQP, PPAP, IATF
• Lean Manufacturing and line balancing
• MES and manufacturing traceability systems