Manufacturing Engineer – Fastening Systems

Job Description

Responsibilities

Process Design Development

• Develop and optimise engine/transmission assembly process flows, line layouts, and workstation designs.
• Design assembly stations with a strong focus on safety, ergonomics, and manufacturability.
• Develop fastening process sheets, work instructions, and standard operating procedures (SOPs).
• Support new model launches, engineering changes, and process improvements.
• Evaluate assembly feasibility and incorporate Design for Manufacturing (DFM) and Design for Assembly (DFA) principles.

Fastening System Engineering

• Design and specify fastening systems including bolts, screws, rivets, clips, adhesives, and welds.
• Develop and validate fastening parameters including torque-to-yield, clamp load, and joint integrity requirements.
• Plan and execute fastening validation activities including torque-tension, tensile, and fatigue testing.
• Analyse fastening failures and develop corrective actions to improve system reliability.

Equipment Tooling

• Select and specify fastening equipment including torque tools, automated fastening systems, and error-proofing solutions.
• Support installation, commissioning, and process validation activities.
• Coordinate with suppliers regarding fastener sourcing, qualification, and quality performance.

Quality Continuous Improvement

• Conduct root cause analysis for fastening-related quality concerns including loose fasteners, cross-threading, and joint failures.
• Perform Process Failure Mode and Effects Analysis (PFMEA) and support Control Plan development.
• Lead Lean Manufacturing, Kaizen, and Six Sigma initiatives to improve productivity and reduce waste.
• Provide technical support to manufacturing plants for process optimisation and issue resolution.

Safety Compliance

• Ensure compliance with corporate, industry, and regulatory standards.
• Conduct manufacturing risk assessments and implement safety improvements.
• Apply applicable fastening standards including SAE, ISO, and IFI requirements.

Procurement Documentation

• Prepare and issue Requests for Quotation (RFQs).
• Evaluate supplier quotations based on technical and commercial requirements.
• Support purchase order processing in accordance with procurement procedures.
• Manage OEM documentation including reliability and maintainability reports, spare parts lists, manuals, preventive maintenance plans, and final installation drawings.
• Track documentation delivery and resolve supplier documentation gaps.

Education

Diploma or Bachelor’s Degree in:

• Mechanical Engineering
• Manufacturing Engineering
• Automotive Engineering
• Industrial Engineering
• Electrical Engineering

Experience

• 2-5 years of experience in manufacturing engineering, assembly engineering, or fastening systems engineering.
• Experience in engine, transmission, powertrain, automotive, or high-volume manufacturing environments preferred.
• Experience supporting new product launches and process implementation activities.

Technical Skills

• Strong understanding of engine/transmission assembly processes.
• Knowledge of fastener selection, torque-tension relationships, clamp load, and joint design principles.
• Experience with automated and robotic fastening systems.
• Familiarity with fastening validation techniques and audit tools.
• Proficiency in CAD tools such as CATIA and AutoCAD.
• Working knowledge of PFMEA, Control Plans, and GDT.
• Understanding of Lean Manufacturing and Six Sigma methodologies.
• Strong problem-solving and root cause analysis skills.

Professional Skills

• Strong communication and presentation skills.
• Ability to work effectively within cross-functional teams.
• Effective project coordination and stakeholder management skills.
• Willingness to work shifts and relocate based on business and project requirements.

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