MANUFACTURING ENGINEER (JIGS & FIXTURES)

POSITION SUMMARY

The Manufacturing Engineer is responsible for transforming high-precision fixture designs into physical assets with a focus on technical excellence and financial efficiency. This role requires a blend of advanced CNC/CAM expertise and rigorous project management to ensure parts are machined "Right First Time" within the estimated budget and hours.

CORE RESPONSIBILITIES

1. CNC / CAM & Process Strategy

• High-Precision Programming: Develop 3-axis and 5-axis CNC programs using advanced CAM software, optimizing tool paths for surface finish and accuracy.
• Manufacturing Methods: Identify the most efficient manufacturing sequence to ensure dimensions meet customer specifications (±5 to ±10 microns).
• Surface Treatment Planning: Calculate and apply precise machining allowances to account for post-processing requirements like Hard Anodizing, ENP, or Heat Treatment.

2. Material Expertise & Development

• Metallic Machining: Implement specialized cutting strategies for Stainless Steel (work-hardening prevention) and Aluminium (high-speed machining with superior surface finish).
• Non-Metallic & Polymer Development: Lead the machining and development of TPU (Thermoplastic Polyurethane) and other engineering plastics. This includes managing material compression during clamping and selecting razor-sharp tooling to prevent "burring" or melting.
• Distortion-Free Machining: Develop specialized workholding and stress-relieving machining sequences to prevent warping in thin-walled components.

3. Production Control & Cost Management

• Machining Hour Control: Monitor and control actual machining hours against the pre-defined Estimated Man-Hours. Identify variances and implement corrective actions to prevent cost overruns.
• Efficiency Audits: Continuously review CNC cycle times and setup procedures to align shop-floor performance with the commercial estimate.
• Assembly Engineering: Lead the physical integration of mechanical, pneumatic, and electrical subsystems, ensuring zero interference during the final build.

TECHNICAL REQUIREMENTS

1. Education & Experience

• Qualification: B.E. / B.Tech in Manufacturing, Mechanical, or Production Engineering.
• Experience: 4–7 years in high-precision CNC machining and toolroom operations.
• Domain Expertise: Proven experience in managing "Estimate vs. Actual" machining costs for custom tooling projects.

2. Software & Technical Proficiency

• CAM Mastery: Expert proficiency in Mastercam, NX CAM, or PowerMill.
• Project Tracking: Familiarity with ERP systems or Excel-based tracking for monitoring machining hours and production milestones.
• Metrology: Hands-on experience with CMM, 3D scanning, and high-precision manual gauging.

3. Specialized Knowledge

• Material Science: Understanding of the thermal and mechanical properties of Stainless Steel, Aluminium alloys, and the elastic behaviour of TPU during machining.
• Tooling Economics: Ability to select cutting tools that balance high-speed removal with long-term cost-efficiency.

KEY PERFORMANCE INDICATORS (KPIs)

1. Labor Efficiency: Percentage variance between Estimated vs. Actual machining hours (Target: <5% variance).
2. Quality Rate: Success rate of First Article Inspection (FAI) with zero rework due to machining errors or material distortion.
3. Material Integrity: Zero part rejections due to improper handling of specialized materials (e.g., melting of TPU or work-hardening of SS).
4. On-Time Delivery: Adherence to the production schedule for final fixture assembly.