Machine Shop Engineer

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1. Role Purpose

To execute, monitor, and improve precision machining operations on CNC, VMC, and conventional machines for manufacturing high-accuracy aerospace, defense, or heavy engineering components. The role demands technical knowledge of machining processes, machine settings, tooling systems, fixture design, quality control practices, and a strong focus on safety and continuous improvement. The Machine Shop Engineer shall be responsible for achieving production targets while maintaining the highest quality standards and operational discipline. Candidates with prior experience in aerospace, defence, or missile manufacturing environments are strongly preferred due to the precision, compliance, and process discipline required in such industries.

2. Key Responsibilities

A. Machine Operation & Programming

• Operate CNC and VMC machines with precision for turning, milling, drilling, reaming, tapping, and other critical machining operations.

• Interpret engineering drawings with detailed GD&T and ensure correct process sequencing.

• Modify and optimize G-code and M-code programs at the machine panel to improve cycle times and Monitor tool offsets, machine wear, and spindle utilization, and update tooling parameters accordingly.

• Conduct first-piece approval and sample inspections before bulk runs. reduce idle time.

• Coordinate with CAM programming team for offline program generation and postprocessing corrections.

B. Production Execution

• Plan and execute machining jobs in line with the daily and weekly production schedules.

• Set up fixtures, clamps, jigs, and work-holding systems to ensure accurate positioning and repeatability.

• Ensure efficient job changeover through SMED (Single Minute Exchange of Die) practices.

• Maintain minimum rejection and achieve First Pass Yield (FPY) for all machined components.

• Maintain accurate batch traceability through ERP and ensure job card compliance.

• Assist in line balancing, bottleneck elimination, and machine loading improvements.

C. Quality & Dimensional Inspection

• Perform in-process checks, post-machining inspection, and maintain inspection logs.

• Use high-precision tools such as bore gauges, micrometres, CMM (if available), and dial indicators.

• Ensure all critical dimensions and tolerances conform to aerospace/defencegrade standards.

• Liaise with the QC team for resolving deviation issues and CAPA implementation.

• Contribute to internal quality audits and continuous improvement initiatives.

D. Maintenance & Machine Health

• Perform daily and weekly preventive maintenance (coolant level checks, lubrication, debris removal, etc.). • Monitor machine alarms and feedback systems, and respond promptly to any fault or alert.

• Report breakdowns through internal escalation protocols and ensure minimum downtime.

• Maintain records of maintenance activities, breakdown analysis, and corrective measures.

• Participate in TPM initiatives and support machine reliability programs.

E. Safety & Process Discipline

• Ensure strict compliance with shop floor safety norms, especially while working with rotating tools and coolant systems.

• Wear appropriate PPE including gloves, goggles, safety shoes, and hearing protection.

• Identify safety hazards and suggest improvements during safety committee meetings.

• Follow work instructions, SOPs, and standard operating cycles strictly.

• Participate in mock drills, fire safety sessions, and hazard communication programs.

3. Educational Qualifications

• Mandatory: Diploma / B.E. / B.Tech. in Mechanical / Production / Industrial Engineering

• Preferred: Certification or industrial training in CNC/VMC operation, basic knowledge of CAM software such as MasterCAM, Siemens NX, or EdgeCAM

4. Experience Requirements

• Minimum 3 years of hands-on shop floor experience in CNC and conventional machining.

• Preference will be given to candidates with prior experience in aerospace, defence manufacturing, missile systems, rocket systems, or heavy engineering industries.

• Proven track record in handling parts for aerospace, defence, oil & gas, or heavy engineering sectors.

• Exposure to machining exotic materials like titanium, Inconel, and special aluminium alloys.

• Experience in close tolerance machining (below 20 microns) and mirror finish components.

5. Technical Competencies

• Machining Operations: Hands-on with CNC, VMC, turning, drilling, tapping, reaming, slotting
• Drawing Interpretation: GD&T symbols, section views, tolerance analysis
• Machine Programming: Basic programming, offsets, wear compensation, controller navigation
• Tooling & Fixturing: Knowledge of HSS, carbide tools, insert grades, and fixture base design
• Measurement Techniques: Manual and digital measurement tools, surface finish gauges, radius gauges
• Productivity Improvements: Kaizen, 5S, reducing idle time, OEE improvement
• Material Knowledge: Machining of aerospace-grade alloys, thermal expansion, work hardening

6. Behavioral Competencies

• Discipline & Punctuality: Adheres to shift timings, respects hierarchy, follows operational discipline
• Problem-Solving: Proactively resolves machining, tolerance, and material handling issues
• Teamwork Collaborates: effectively with QA, maintenance, tool crib, and planning teams
• Continuous Learning: Open to training, feedback, and learning new machine technologies
• Ownership: Takes full accountability for output quality, job card updates, and safety
• Initiative: Identifies areas for productivity and quality improvement and proposes actions

7. Tools & Systems Exposure

• Controllers: Siemens, Fanuc, Haas, Mazak (basic interface knowledge mandatory)

• Measurement Tools: Vernier calliper, micrometre, bore gauge, dial indicator, height gauge

• Software & Systems: CAM software familiarity preferred, ERP for tracking production status (SAP/Oracle)

• Other Tools: Surface finish testers, radius gauges, thread gauges, and comparator stands

8. Working Conditions

• Shift-based job with shop floor deployment (rotational or continuous as per plant norms)

• Involves handling of heavy components, exposure to coolant, chips, and machine noise

• Standing or walking for extended periods during shifts

• Adherence to company-issued PPE and EHS norms mandatory

• Must be able to lift moderate weights and operate hoists or cranes where required

9. Career Progression Path

Machine Shop Engineer → Senior Engineer → Shift In-charge → Deputy Manager / Manager – Machine Shop / Manufacturing → Senior Manager – Production