Design Engineer

Design Engineer Tool Room (Jigs, Fixtures & SPMs)

Department: Tool Room (Corp Engg)Experience: 3 - 4 Years (Tool Room / Fixtures / SPM)Education: B.E. / B.Tech in Mechanical / Mechatronics Eng.Core Software: SolidWorks (3D/2D/Assembly), FEA

POSITION OVERVIEW
The Design Engineer is responsible for end-to-end tool room design of Jigs, Fixtures, Special Purpose Machines (SPMs), and specialized test rigs. The role translates Capex requisitions into robust 3D models and 2D manufacturing drawings with strict GD&T. It demands a strong mechanical foundation combined with fluid power sizing, basic control automation, Industry 4.0 integration, and proactive stakeholder communication from initial concept design through shop-floor commissioning.
KEY RESPONSIBILITIES

• 3D/2D Design & Modeling: Generate 3D concepts and complex assemblies in SolidWorks using Top-Down parametric design. Prepare detailed 2D manufacturing drawings with strict GD&T (ASME Y14.5) and tolerance stack-up analysis.
• Tooling & Welding Fixtures: Design manual, pneumatic, hydraulic, and robotic welding fixtures, accounting for thermal distortion, clamp sequence, ergonomics, and accessibility.
• Test Rig & SPM Design: Design custom Hydro-Pneumatic and Steam Test Rigs incorporating leak testing, pressure-drop mechanics, fluid safety interlocks, and automated sequencing.
• Engineering Analysis & Sizing: Perform structural strength calculations, component sizing, and Static FEA simulations. Select standard elements including LM guides, ball screws, bearings, and power transmission units.
• Fluid Power & Pneumatics/Hydraulics: Perform sizing calculations for pneumatic and hydraulic circuits (actuators, operating pressure, flow rates, stroke, clamp force). Design and integrate clamping circuits, cylinders, manifolds, and sequencing controls.
• Automation, Robotics & Industry 4.0: Collaborate on basic PLC, HMI, and SCADA integration requirements. Integrate smart sensors, IO-Link, data logging, and design robot end-of-arm tooling (EOAT) for robotic cells.
• Stakeholder Communication & Project Delivery: Lead end-to-end project communication across internal stakeholders, end-users, and vendors. Conduct technical design reviews, Capex tracking, and ensure on-time delivery.
• Shop Floor, Proving & Handover: Provide hands-on support to machining teams and vendors during fabrication. Lead fixture proving, tryouts, troubleshooting, and final handover to production.
• Operational Excellence (5S, Kaizen & OSP): Apply 5S principles in design data management. Lead Kaizen tools to reduce cycle times and Out-of-Spec / Out-Source Processing (OSP) costs while maintaining modular design libraries.

TECHNICAL SKILLS & COMPETENCIES
Domain AreaKey Competencies & Technical SkillsCAD & SimulationSolidWorks (3D Solid Modeling, Top-Down Assembly, 2D Drafting), FEA Simulation (Static Analysis).Tooling & Test SystemsJigs & Fixtures, Manual/Robotic Welding Fixtures, SPMs, Hydro-Pneumatic and Steam Test Rigs.Fluid Power & MechanicsPneumatics & Hydraulics circuit design, component sizing, LM guides, ball screws, bearings, toggle clamps.Automation & Smart MfgBasics of PLC, HMI, SCADA, Robotics integration, Industry 4.0 sensors, data logging, IO-Link.Quality & StandardsASME Y14.5 GD&T standards, tolerance stack-up analysis, fitment calculations, machine design principles.
Manufacturing & MaterialsShop floor machining (CNC, Milling, Turning, EDM, Welding), materials selection, heat treatments, surface coatings.Operational Excellence5S principles, Kaizen tools, OSP cost reduction, standard design checklists, modular design libraries.Project & Soft SkillsEnd-to-end ownership, stakeholder communication, vendor coordination, daily MIS (MS Office, Google Workspace).