The Role
Lead NPI and industrialization for aerospace-grade motor assemblies and electro-mechanical systems. Own assembly excellence, fixtures, CAD/GD&T review, DFMEA/PFMEA, FAIR/AS9102, supplier development, failure analysis, testing, and cross-functional team leadership to achieve first-time-right production and AS9100 compliance.
Summary Generated by Built In
This role is a critical leadership position responsible for driving industrialization, assembly excellence, and reliability engineering of aerospace-grade motor assemblies and electro-mechanical systems.
The candidate must demonstrate deep domain expertise in precision motor assembly, aerospace standards, complex mechanical systems, and NPI execution, along with strong capability in team leadership, supplier collaboration, and customer-facing problem resolution.
1. Electro mechanical Assembly Expertise
- Lead manufacturing and assembly of high-precision aerospace motors including:
- BLDC / AC / DC motors
- Servo motors / actuators
- High-speed rotating systems
- BLDC / AC / DC motors
- Deep understanding of:
- Rotor-stator assembly alignment
- Dynamic balancing (G-level accuracy)
- Bearing selection, preload, lubrication techniques
- Winding processes, insulation systems, varnishing
- Rotor-stator assembly alignment
- Address critical parameters:
- Runout, concentricity, vibration limits
- Thermal expansion & heat dissipation
- Noise and performance stability
- Runout, concentricity, vibration limits
- Ensure compliance with aerospace tolerances and traceability requirements
- Manage full assembly lifecycle of electro-mechanical products, including:
- Motors + Controllers + Harnessing + Sensors
- Motors + Controllers + Harnessing + Sensors
- Integration challenges:
- EMI/EMC considerations
- Thermal and structural interactions
- Precision fitment of mechanical + electrical interfaces
- EMI/EMC considerations
- Validate system-level performance under:
- Vibration, shock, thermal cycling
- Endurance / life-cycle testing
- Vibration, shock, thermal cycling
- Lead end-to-end aerospace NPI programs:
- Design transfer → Proto → EVT / DVT / PVT → Mass production
- Design transfer → Proto → EVT / DVT / PVT → Mass production
- Drive:
- DFM / DFA optimization
- Manufacturing readiness reviews (MRR)
- Risk mitigation plans (DFMEA / PFMEA)
- DFM / DFA optimization
- Establish:
- Process flow diagrams, control plans, work instructions
- Process flow diagrams, control plans, work instructions
- Ensure readiness for:
- AS9100 audit compliance
- First-time-right production
- AS9100 audit compliance
- Expert-level capability in CAD drawing reading and interpretation:
- GD&T (ASME Y14.5 standard preferred)
- Tolerance stack-up analysis
- Critical-to-function feature identification
- GD&T (ASME Y14.5 standard preferred)
- Ability to:
- Identify manufacturability risks directly from drawings
- Suggest design corrections for assembly feasibility
- Identify manufacturability risks directly from drawings
- Work with tools:
- Creo / NX / SolidWorks
- Creo / NX / SolidWorks
- Drive engineering change management (ECR/ECO)
- Design and validate:
- Assembly fixtures (alignment, press-fit tools)
- Coil winding fixtures
- Rotor balancing setups
- Assembly fixtures (alignment, press-fit tools)
- Knowledge of:
- Pneumatic / hydraulic tools
- Torque control systems
- Automated assembly stations
- Pneumatic / hydraulic tools
- Focus on:
- Error-proofing (poka-yoke)
- Repeatability & precision
- Cycle time reduction
- Error-proofing (poka-yoke)
- Lead FAIR (First Article Inspection Report) execution as per AS9102
- Strong exposure to:
- AS9100, NADCAP (preferred)
- AS9100, NADCAP (preferred)
- Drive:
- APQP, PPAP (adapted for aerospace)
- Control of special processes
- APQP, PPAP (adapted for aerospace)
- Perform:
- Root cause analysis (8D, Fishbone, 5 Why)
- Failure investigations (fractography, wear analysis, misalignment)
- Root cause analysis (8D, Fishbone, 5 Why)
- Extensive travel to supplier and customer locations for:
- Process audits
- Technical issue resolution
- Qualification activities
- Process audits
- Manage:
- Supplier capability assessments
- Critical component validation (laminations, bearings, shafts)
- Supplier capability assessments
- Act as technical leader in:
- Customer escalations
- On-site troubleshooting of assembly failures
- Customer escalations
- Lead cross-functional teams:
- Mechanical / Manufacturing / Quality engineers
- Mechanical / Manufacturing / Quality engineers
- Drive:
- Performance management
- Capability building (technical mentoring)
- Performance management
- Establish:
- Strong engineering governance
- Structured problem-solving culture
- Strong engineering governance
- B.E / B.Tech / M.E in Mechanical Engineering
- 15–20 years in:
- Aerospace / defense / high-reliability EMS
- Motor assembly and electro-mechanical systems
- NPI and manufacturing engineering
- Aerospace / defense / high-reliability EMS
- Aerospace motor assembly fundamentals
- GD&T mastery & tolerance stack analysis
- FAIR (AS9102), APQP, PPAP
- Fixture/tooling design and validation
- Failure analysis & reliability engineering
- Supplier development and audits
- Lean manufacturing & Six Sigma
Skills Required
- B.E / B.Tech / M.E in Mechanical Engineering
- 15-20 years experience in aerospace, defense, or high-reliability EMS
- Proven experience with motor assembly and electro-mechanical systems and end-to-end NPI
- Expertise in precision motor technologies (BLDC/AC/DC, servo motors, high-speed rotating systems)
- GD&T mastery and tolerance stack-up analysis (ASME Y14.5 preferred)
- Experience with FAIR (AS9102), AS9100, APQP and PPAP processes
- Familiarity with NADCAP processes and audits
- CAD proficiency: Creo, NX, SolidWorks
- Fixture, jig and tooling design and validation experience (assembly fixtures, coil winding, balancing setups)
- Risk mitigation and quality tools: DFMEA/PFMEA, root cause analysis (8D, Fishbone, 5 Why)
- Supplier development, audits, and on-site troubleshooting experience; willingness to travel extensively
- Lean manufacturing and Six Sigma experience
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The Company
What We Do
Cyient DLM provides end-to-end design-led manufacturing (DLM) solutions, integrating electronics and mechanical capabilities. It specializes in high-mix, high-reliability solutions for safety-critical applications in highly regulated industries, including aerospace, defense, healthcare, and industrial sectors, managing the product life cycle from concept through certification.
