Sr. Engineer (Fixture Design)

Role & responsibilities

1. Fixture Design & Development

• Design machining fixtures (manual, pneumatic, hydraulic) for turning, milling, drilling, and boring operations on aluminum forged parts.
• Apply 3-2-1 location principles and GD&T interpretation to define clamping and location strategy.
• Prepare detailed 2D and 3D CAD models/drawings using software like SolidWorks, CATIA, or Creo.
• Optimize fixture design for cycle time, repeatability, operator ergonomics, and ease of maintenance.

2. Tooling Design & Selection

• Design and specify cutting tools (turning inserts, end mills, drills, reamers, form tools) based on material, machining operation, and process parameters.
• Collaborate with tool suppliers for tool trials, life improvement, and cost optimization.
• Maintain a library of standard tools and issue tooling sheets for shopfloor reference.

3. Process & Application Engineering Support

• Collaborate with CNC programming, process engineering, and production teams to finalize fixture & tool specifications based on machining sequence.
• Support machine prove-outs, tool path validation, and process capability improvement.
• Troubleshoot fixture/tool-related issues such as chatter, poor finish, dimensional variation, or tool breakage.

4. Validation & Trials

• Participate in trial runs and fixture/tool validation during new product development (NPD) and production ramp-up.
• Drive continuous improvement by capturing learnings from production feedback and implementing design changes.

5. Cost, Quality, and Standardization

• Ensure fixture and tooling design meets cost, performance, and quality standards.
• Support the standardization of fixtures and tools across similar components to reduce inventory and setup time.
• Contribute to process cost reduction through design innovation.

6. Documentation & Compliance

• Prepare fixture assembly drawings, BOMs, and operating manuals.
• Maintain design history and revision control in accordance with ISO/IATF requirements.

Skills & Competencies:

• Proficiency in CAD software (SolidWorks, CATIA, Creo, AutoCAD).
• Good understanding of CNC/VMC/HMC operations, machining strategies, and tool paths.
• Strong knowledge of GD&T, machining allowances, and aluminum-specific machining challenges.
• Hands-on experience with fixture validation and tool performance improvement.
• Knowledge of cutting tool geometry, coatings, and materials.
• Exposure to lean manufacturing, Kaizen, and TPM is a plus.
• Strong analytical and problem-solving ability.
• Good communication and collaboration skills with cross-functional teams.

Key Performance Indicators (KPIs):

• % of NPD/fixture/tool designs delivered on time.
• Number of successful implementations with zero rework/modification.
• Cycle time reduction achieved due to fixture/tool improvements.
• Tool life improvement and cost per part reduction.
• First pass yield improvement due to improved clamping and tool design.