Manufacturing Engineer - EE & Battery Integration

<div>Job Summary:</div><p style="text-align:justify;">Dynamic Manufacturing Engineer with specialized expertise in integrating complex electrical systems and high-voltage battery assemblies for next-generation aircraft with Proven track record in bridging the gap between design and the shop floor through robust DFM/DFA strategies, IPC-compliant process development, and real-time troubleshooting. Expertise in scaling battery enclosure assembly, thermal management, and advanced wire harness routing from prototype to serial production in highly regulated aerospace environments.<br><br>Role &amp; Responsibilities:<br><strong>I. Design Integration &amp; Strategy (The "Before the Build" Phase)</strong></p><ul style="margin-top:0in;" type="disc"><li><strong>Support DFM/DFA activities</strong> during design reviews to ensure the manufacturability and serviceability of complex electrical systems.</li><li><strong>Define wire routing strategies</strong> ensuring safety, serviceability, and strict compliance with aerospace standards.</li><li><strong>Collaborate closely with design, quality, and supply chain teams</strong> to optimize build flow and reduce cycle time from the outset.</li><li><strong>Work with suppliers and internal teams</strong> to validate battery module assembly techniques and specialized tooling.</li></ul><div><strong>II. Process Development &amp; Documentation</strong></div><ul style="margin-top:0in;" type="disc"><li><strong>Develop and implement manufacturing processes</strong> for aircraft battery installation, including enclosure assembly, mounting, thermal management, and electrical interfacing.</li><li><strong>Create and validate build processes</strong> for wiring harness routing, terminations, and connector assemblies.</li><li><strong>Develop Standard Operating Procedures (SOPs), Manufacturing Instructions (MIs)</strong>, and detailed inspection criteria.</li><li><strong>Manage production data</strong>, including MBOM (Manufacturing Bill of Materials) preparation, Process Flow Diagrams, Control Plans, and PPAP/FAI documentation.</li></ul><div><strong>III. Shop Floor Execution &amp; Troubleshooting</strong></div><ul style="margin-top:0in;" type="disc"><li><strong>Provide hands-on support to technicians</strong> on the shop floor during both prototype and serial production phases.</li><li><strong>Troubleshoot wiring and battery integration issues in real-time</strong>, implementing immediate corrective actions to maintain build schedules.</li><li><strong>Support the creation of harness assembly boards</strong>, work instructions, and functional test procedures.</li><li><strong>Drive Root Cause Analysis (RCA)</strong> for non-conformances and lead continuous improvement efforts to prevent recurrence.</li></ul><div><strong>Technical Skills &amp; Competencies</strong></div><div><strong>Electrical Mastery:</strong></div><ul style="margin-top:0in;" type="disc"><li><strong>Technical Drawing Fluency:</strong> Ability to read wiring harness drawings, circuit diagrams, connector views, and terminal callouts.</li><li><strong>Component Expertise:</strong> Deep understanding of wire grades/types, terminal selection, crimp specifications, sealing systems, splice methods, and protection standards (taping/sleeving).</li><li><strong>System Knowledge:</strong> Understanding of PCB interfaces, wiring harnesses, and busbar design.</li></ul><div><strong>Standards &amp; Quality:</strong></div><ul style="margin-top:0in;" type="disc"><li><strong>Industry Standards:</strong> Good understanding of <strong>IPC/WHMA-A-620</strong> (preferred), <strong>IPC-A-600/610</strong>, and <strong>IPC-7711C/7721C</strong>.</li><li><strong>Validation:</strong> Proficiency with crimp height charts and pull-force standards.</li><li>Exposure to QMS standards <strong>AS9100D&nbsp;</strong>is preferred.</li><li><strong>Regulatory Familiarity:</strong> Familiarity with international standards (IEC, IS, UL, CE, RoHS, EMC/EMI).</li></ul><div><strong>Software &amp; Systems:</strong></div><ul style="margin-top:0in;" type="disc"><li><strong>ECAD Tools:</strong> Exposure to harness design software (<strong>Capital, Zuken</strong>) is a significant advantage.</li><li><strong>CATIA Electrical harness module &amp; PLM&nbsp;</strong>exposure is preferred</li><li><strong>MS office / Google suite&nbsp;</strong>proficiency</li></ul><div><strong>Qualifications :</strong><br>- Bachelor’s degree in Electrical, Electronics or any related field.<br>- 4+ Years of Experience in ME E&amp;E Integration activities in Aerospace industry preferred.<br><br><strong>Work Location: Kelambakkam, Chennai, Tamil Nadu, India.</strong><br><strong>Job Type: Full-time, Work from office.</strong></div>