Design Manager

1. GENERAL PURPOSE OF THE ROLE:

To strategically lead and manage the Mechanical Design department, ensuring the delivery of accurate, efficient, cost-effective, and innovative mechanical design solutions for automation projects. The role includes team leadership, process enforcement, quality adherence, project planning, cross-functional coordination, customer interface, and continuous improvement.

2. RESPONSIBILITIES (Detailed at Micro Level):

2.1 Technical Design Management:

• Create, review, and approve conceptual designs, detailed designs, and final designs for SPM, EOL, BIW, and Automation Cells.
• Validate mechanical strength, motion studies, interference, fits, thermal tolerances, vibration tolerances, etc.
• Perform root cause analysis for all design-related field failures and initiate permanent countermeasures.
• Own and enforce compliance with CE, ISO, and BIS standards.
• Drive platform-based design and modularity to reduce design lead time.
• Integrate design with electrical/control requirements, layout constraints, and operator safety.

2.2 Time Management & Planning:

• Prepare macro and micro-level design timelines for every project with weekly milestones.
• Allocate daily design tasks and review completion on an hourly/daily basis.
• Forecast design hours and resource availability based on incoming and running projects.
• Maintain a weekly design status tracker shared with management and PM team.

2.3 Cost & Budget Control:

• Estimate and monitor design costs in line with project budgets.
• Optimise design for part count, manufacturability, weight, and machining complexity.
• Justify expensive/non-standard part usage in front of management.
• Track value engineering (VE) contributions from the design team.

2.4 Process Adherence & Governance:

• Enforce the use of design SOPs, DFMEA, DVP, and Poka-Yoke principles.
• Mandate version control, part naming standards, drawing revision systems.
• Review and sign off GA, layout, assembly, and part drawings for each project.
• Lead internal audits, checklists, and design data gate checks before release.

2.5 Feasibility & Risk Evaluation:

• Conduct feasibility study reports before design start.
• Identify design risks (thermal, vibration, accessibility, alignment, wear) and propose mitigations.
• Ensure tooling and component tolerances are within practical manufacturing limits.

2.6 Interdepartmental & Customer Coordination:

• Attend customer technical discussions and clarify design expectations and constraints.
• Coordinate with purchase for long lead item design freezes and technical vetting.
• Support production and quality during pre-dispatch inspection and FATs.

2.7 Team Development & Mentorship:

• Conduct monthly performance reviews for each designer with documented feedback.
• Create technical growth plans and upskilling targets for each designer.
• Allocate mentorship and peer review responsibilities internally.
• Identify and replace underperforming team members via documented PIP.

2.8 Documentation & Traceability:

• Maintain 100% drawing traceability and archival in digital systems (PLM/PDM).
• Ensure design handover package includes drawings, BOM, checklist, DFMEA, risk register.
• Submit weekly design metrics (release %, error rate, rework %).

2.9 Innovation, IP & Standardization:

• Lead concept generation workshops; log and evaluate innovative ideas monthly.
• Drive patent filings or innovation disclosures every year.
• Create and maintain a standard parts library with technical validation.

2.10 Supplier & Vendor Coordination:

• Vet mechanical bought-out designs before PO release.
• Participate in vendor audits for mechanical component quality.
• Approve or reject component substitution requests.

3. ACCOUNTABILITY (Non-Negotiable Outcomes):

• Timely release of complete, error-free design packages.
• Design output adherence to cost targets (design-to-cost compliance).
• Technical closure of all field complaints related to design.
• Performance improvement for under-performing designers.
• Compliance with internal audits and external customer design reviews.
• Contribution to knowledge database and standardization.

4. AUTHORITY (Decisional Rights):

• Approve all final drawings and BOQs.
• Approve leave, appraisal, and escalation of design team members.
• Stop project progress if safety or design integrity is compromised.
• Approve vendor design deviations and non-standard parts.
• Decide training needs and certification plans for team.
• Accept or reject customer-requested design changes with cost/time implications.

5. QUALIFICATIONS:

• B.E. / B.Tech. / M.Tech. in Mechanical Engineering / Mechatronics / Robotics
• Certifications in GD&T, DFMEA, CAD platforms, and FEA preferred.

6. EXPERIENCE:

• 18+ years in machine design, with 5+ years in design team leadership.
• Proven experience in high-speed automation, jigs/fixtures, or SPM.

7. TOOLS & SOFTWARE PROFICIENCY:

• CAD: SolidWorks, AutoCAD, NX, Solid Edge (mandatory)
• FEA: ANSYS, Solid-works Simulation
• PLM/PDM: Vault, Teamcenter or equivalent
• Microsoft Project / Excel / Power BI (for reporting)

8. PERFORMANCE INDICATORS (KPIs):

• On-time release rate less than 95%
• Design rework rate less than 2%
• % Standardization in new designs more than 50%
• Design cost vs target variance less than 5%
• Number of VE initiatives accepted more than 4/year
• Average rating from production/QA more than 8/10

9. WORK ENVIRONMENT & EXPECTATIONS:

• Location: Pune office, with availability for shopfloor and customer visits
• Availability: As per company policy
• Confidentiality: Strictly adhere to IP and data protection policies
• Travel: 10% domestic; occasional international (Germany, ASEAN)