Manager Facilities Engineer

Caterpillar Inc; Gilgit Division; On-site; PKR 6,000,000 - 12,000,000; Full time

Job summary

Caterpillar Inc is seeking an Engine Genset Test Manufacturing Engineering Manager responsible for leading the manufacturing engineering, process development, automation, test technology, capital projects, and continuous improvement for engine and generator set testing operations.

The role ensures robust, efficient, and reliable testing processes that support production, new product introduction, quality compliance, capacity expansion, and operational excellence.

Job description

Job Summary

The Engine Genset Test Manufacturing Engineering Manager is responsible for leading the manufacturing engineering, process development, automation, test technology, capital projects, and continuous improvement functions for engine and generator set testing operations. The role ensures robust, efficient, and reliable testing processes that support production, new product introduction, quality compliance, capacity expansion, and operational excellence.

This position drives engineering solutions for engine hot testing, genset load testing, emissions measurement, data acquisition systems, automation, and test facility modernization while optimizing safety, quality, delivery, and cost performance.

Key Responsibilities

Manufacturing Engineering Leadership

• Lead Engine and Genset Test Manufacturing Engineering activities across the facility.
• Develop manufacturing engineering strategies aligned with business objectives.
• Establish engineering standards, testing specifications, and best practices.
• Support production growth through capacity planning and technology deployment.
• Drive operational excellence through process optimization and innovation.
• Build a high-performance engineering organization focused on continuous improvement.

Engine Genset Test Process Engineering

Develop, optimize, and standardize:

• Hot test operations
• Engine performance verification
• Fuel consumption measurement
• Emissions testing
• End-of-line testing
• Functional validation
• Durability testing processes
• Troubleshooting and diagnostic processes

Genset Test Processes

• Load testing procedures
• Electrical performance testing
• Frequency and voltage regulation testing
• Noise and vibration testing
• Reliability validation testing
• Customer acceptance testing
• Final inspection and release testing

Key Deliverables

• Improved throughput and productivity
• Reduced test cycle time
• Enhanced first-pass yield
• Improved equipment utilization
• Standardized testing methodology
• Reduced quality defects and rework

Test Automation Digital Manufacturing

Lead development and implementation of:

• Automated test systems (PUMA)
• PLC-based test controls
• SCADA systems
• Data acquisition systems (DAQ)
• Engine control integration
• Genset controller integration
• Digital manufacturing solutions
• Real-time monitoring systems
• IIoT and Industry 4.0 applications
• Manufacturing analytics dashboards

Responsibilities

• Establish automated testing standards.
• Improve test data accuracy and traceability.
• Develop smart manufacturing solutions.
• Drive paperless operations and digital workflows.
• Support factory connectivity and data analytics initiatives.

Test Equipment Facility Engineering

Responsible for engineering and optimization of:

• Engine dynamometers
• Hydraulic dynamometer systems
• Resistive and reactive load banks
• Fuel systems
• Cooling systems
• Air intake systems
• Exhaust extraction systems
• Emissions measurement systems
• Electrical distribution systems
• High-voltage testing infrastructure
• Instrumentation and sensors
• Calibration systems

Objectives

• Increase equipment capability.
• Improve test cell utilization.
• Optimize facility layout and workflow.
• Enhance reliability and maintainability.

New Product Introduction (NPI) Industrialization

• Lead test process development for new engine and genset products.
• Support APQP and product launch activities.
• Develop Process Flow Diagrams (PFDs).
• Create PFMEA and Control Plans.
• Conduct process validation and capability studies.
• Support pilot builds and production trials.
• Ensure smooth product launches with minimal disruption.

Capital Projects Capacity Expansion

• Lead planning and execution of capital investment projects.
• Develop CAPEX business cases.
• Define technical specifications for new test equipment.
• Manage supplier selection and technical evaluations.
• Coordinate installation and commissioning activities.
• Deliver projects on schedule and within budget.

Typical Projects

• New engine test cells
• New genset test bays
• Load bank installations
• Emissions laboratories
• Automated testing systems
• Industry 4.0 implementation
• Capacity expansion programs
• Facility modernization initiatives

Continuous Improvement Operational Excellence

• Drive Lean Manufacturing and Six Sigma initiatives.
• Improve Overall Equipment Effectiveness (OEE).
• Reduce testing costs and cycle times.
• Improve First Pass Yield (FPY).
• Lead Value Stream Mapping activities.
• Conduct Kaizen workshops.
• Implement best practices across manufacturing operations.

Quality Engineering Support

• Establish robust process controls for testing operations.
• Analyze quality and test failure trends.
• Lead root cause investigations.
• Implement corrective and preventive actions.
• Support customer audits and regulatory compliance audits.
• Improve test accuracy and repeatability.

Focus Areas

• Test repeatability
• Data integrity
• Process capability
• Defect prevention
• Warranty reduction
• Customer satisfaction

Safety Regulatory Compliance

• Ensure compliance with all EHS and plant safety requirements.
• Lead risk assessments for fuel systems, rotating machinery, and high-voltage equipment.
• Develop safe testing procedures and standards.
• Support ISO 9001, ISO 14001, and ISO 45001 requirements.
• Ensure compliance with emissions and customer-specific testing regulations.
• Promote a zero-incident safety culture.