The Gear Manufacturing Engineer is responsible for developing, optimizing, implementing, and supporting gear manufacturing processes to ensure the production of high-quality gears for automotive transmissions and related applications. This role involves process development, implementing, troubleshooting, continuous improvement, and cross-functional collaboration with design, quality, production teams, and suppliers.
The Candidate will:
- Develop and implement manufacturing processes for gear production, from raw material to final machined gears, including gear cutting, chamfering, heat treatment, shot peening, and finishing operations.
- Collaborate with manufacturing, product engineering and design teams to ensure manufacturability and compliance with specifications.
- Review product engineering gear prints
- Analyze and resolve manufacturing issues related to gear quality, dimensional accuracy, and surface finish.
- Support new product launches by developing process documentation, work instructions, and training materials, such as process sheets, process flow charts.
- Develop PFMEA documentation and lead PFMEA workshops. Create control plans
- Support production of prototypes parts according to the process in serial production, (Desing for Assembly – DFA and Design for manufacturing – DFM), perform tryouts & PPAP and validation process.
- Lead root cause analysis and corrective actions for gear-related manufacturing defects or failures.
- Optimize manufacturing processes for efficiency, cost, and quality using Lean and Six Sigma methodologies.
- Specify and procure gear manufacturing equipment, fixtures, tooling. Create technical documentation for sourcing process, review potential suppliers’ proposals, select winning supplier, perform equipment pre-acceptance at the selected supplier.
- Define process parameters to meet serial production quality requirements.
- Lead for Gear NVH at EOL acceptability, specifications, requirements and 1st time capability
- Design gear tooling such as hob cutters, broach, grinding and honing wheels. Perform tool roll-out analysis, including process variations.
- Work closely with metrology, inspection, and quality teams to ensure proper measurement and quality control of gears, define correct drawing specifications and control (MSA, critical characteristics, GD&T).
- Stay current with the latest trends and technologies in gear manufacturing, including advancements in machining, automation, and inspection.
- Lead innovation projects for new potential processes to test feasibility and economic impact
Basic Qualifications:
- Bachelor’s degree in Mechanical Engineering or a related degree field
- 5 years of experience
- Experience with gear manufacturing processes such as hobbing, shaping, skiving, grinding, honing, shot peening, and heat treatment
- Knowledge of gear design, GD&T, and quality standards (e.g., AGMA, ISO, DIN).
- Proficiency with CAD/PLM tools (e.g., NX, CATIA, Teamcenter) and gear analysis software (e.g., MASTA, LDP, KissSoft)
- Knowledge on different teeth measurements methods (inline, offline, visual scan, NVH)
Preferred Qualifications:
- Masters Degree in Engineering
- Experience in automotive or high-volume manufacturing environments.
- Familiarity with advanced gear inspection techniques (CMM, scanning, etc.).
- Experience with process automation, advanced manufacturing process, and continuous improvement initiatives
- Knowledge of Lean Manufacturing and Six Sigma principles.