1. GENERAL PURPOSE OF THE ROLE:
To strategically lead and manage the Mechanical Design department, ensuring the delivery of accurate, efficient, cost-effective, and innovative mechanical design solutions for automation projects. The role includes team leadership, process enforcement, quality adherence, project planning, cross-functional coordination, customer interface, and continuous improvement.
2. RESPONSIBILITIES (Detailed at Micro Level):
2.1 Technical Design Management:
- Create, review, and approve conceptual designs, detailed designs, and final designs for SPM, EOL, BIW, and Automation Cells.
- Validate mechanical strength, motion studies, interference, fits, thermal tolerances, vibration tolerances, etc.
- Perform root cause analysis for all design-related field failures and initiate permanent countermeasures.
- Own and enforce compliance with CE, ISO, and BIS standards.
- Drive platform-based design and modularity to reduce design lead time.
- Integrate design with electrical/control requirements, layout constraints, and operator safety.
2.2 Time Management & Planning:
- Prepare macro and micro-level design timelines for every project with weekly milestones.
- Allocate daily design tasks and review completion on an hourly/daily basis.
- Forecast design hours and resource availability based on incoming and running projects.
- Maintain a weekly design status tracker shared with management and PM team.
2.3 Cost & Budget Control:
- Estimate and monitor design costs in line with project budgets.
- Optimise design for part count, manufacturability, weight, and machining complexity.
- Justify expensive/non-standard part usage in front of management.
- Track value engineering (VE) contributions from the design team.
2.4 Process Adherence & Governance:
- Enforce the use of design SOPs, DFMEA, DVP, and Poka-Yoke principles.
- Mandate version control, part naming standards, drawing revision systems.
- Review and sign off GA, layout, assembly, and part drawings for each project.
- Lead internal audits, checklists, and design data gate checks before release.
2.5 Feasibility & Risk Evaluation:
- Conduct feasibility study reports before design start.
- Identify design risks (thermal, vibration, accessibility, alignment, wear) and propose mitigations.
- Ensure tooling and component tolerances are within practical manufacturing limits.
2.6 Interdepartmental & Customer Coordination:
- Attend customer technical discussions and clarify design expectations and constraints.
- Coordinate with purchase for long lead item design freezes and technical vetting.
- Support production and quality during pre-dispatch inspection and FATs.
2.7 Team Development & Mentorship:
- Conduct monthly performance reviews for each designer with documented feedback.
- Create technical growth plans and upskilling targets for each designer.
- Allocate mentorship and peer review responsibilities internally.
- Identify and replace underperforming team members via documented PIP.
2.8 Documentation & Traceability:
- Maintain 100% drawing traceability and archival in digital systems (PLM/PDM).
- Ensure design handover package includes drawings, BOM, checklist, DFMEA, risk register.
- Submit weekly design metrics (release %, error rate, rework %).
2.9 Innovation, IP & Standardization:
- Lead concept generation workshops; log and evaluate innovative ideas monthly.
- Drive patent filings or innovation disclosures every year.
- Create and maintain a standard parts library with technical validation.
2.10 Supplier & Vendor Coordination:
- Vet mechanical bought-out designs before PO release.
- Participate in vendor audits for mechanical component quality.
- Approve or reject component substitution requests.
3. ACCOUNTABILITY (Non-Negotiable Outcomes):
- Timely release of complete, error-free design packages.
- Design output adherence to cost targets (design-to-cost compliance).
- Technical closure of all field complaints related to design.
- Performance improvement for under-performing designers.
- Compliance with internal audits and external customer design reviews.
- Contribution to knowledge database and standardization.
4. AUTHORITY (Decisional Rights):
- Approve all final drawings and BOQs.
- Approve leave, appraisal, and escalation of design team members.
- Stop project progress if safety or design integrity is compromised.
- Approve vendor design deviations and non-standard parts.
- Decide training needs and certification plans for team.
- Accept or reject customer-requested design changes with cost/time implications.
5. QUALIFICATIONS:
- B.E. / B.Tech. / M.Tech. in Mechanical Engineering / Mechatronics / Robotics
- Certifications in GD&T, DFMEA, CAD platforms, and FEA preferred.
6. EXPERIENCE:
- 18+ years in machine design, with 5+ years in design team leadership.
- Proven experience in high-speed automation, jigs/fixtures, or SPM.
7. TOOLS & SOFTWARE PROFICIENCY:
- CAD: SolidWorks, AutoCAD, NX, Solid Edge (mandatory)
- FEA: ANSYS, Solid-works Simulation
- PLM/PDM: Vault, Teamcenter or equivalent
- Microsoft Project / Excel / Power BI (for reporting)
8. PERFORMANCE INDICATORS (KPIs):
- On-time release rate less than 95%
- Design rework rate less than 2%
- % Standardization in new designs more than 50%
- Design cost vs target variance less than 5%
- Number of VE initiatives accepted more than 4/year
- Average rating from production/QA more than 8/10
9. WORK ENVIRONMENT & EXPECTATIONS:
- Location: Pune office, with availability for shopfloor and customer visits
- Availability: As per company policy
- Confidentiality: Strictly adhere to IP and data protection policies
- Travel: 10% domestic; occasional international (Germany, ASEAN)
