Engineering Lead - DFM

Job Description

Business Unit:EPSMobilityRole:DFM Leader - MotorWe are seeking a seasoned engineering leader to own end?to?end design and industrialization of traction motors and related sub-systems (e.g., rotor/stator stacks, housings, shafts, bearings, cooling systems, encapsulation, sensors). This role combines deep product design expertise with manufacturing, supply chain, operations, quality, and safety leadership to deliver robust, cost?effective, and scalable EV motor platforms.Key Responsibilities1) Design Leadership & Product ArchitectureOwn the product architecture for traction motors across multiple vehicle platforms (power, torque, efficiency, NVH, durability, thermal, packaging).Drive concept-to-launch lifecycle: requirements, system architecture, trade studies, CAD, CAE, prototyping, V&V, DV/PV, and ramp to mass production.Establish and enforce design standards, design reviews, configuration control, and PLM governance.Champion modularity and platform reuse to reduce complexity, cost, and time-to-market.2) DFM/DFA & IndustrializationTranslate product requirements into manufacture-ready designs: lamination stacking, stator winding (hairpin, distributed, concentrated), impregnation/varnishing, rotor assembly (IPM/SPM), shaft design, balancing, housing and end-cap machining, sealing, and potting.Optimize tolerances and GD&T for manufacturability; conduct DFM/DFA workshops with suppliers and plant engineers.Implement DFMEA/PFMEA, Control Plans, and Process Capability (Cp/Cpk) targets; drive APQP deliverables and PPAP approval.Define end-of-line test strategy (electrical performance, insulation, partial discharge, vibration, noise, thermal run, dimensional checks).3) Operations Interface & Ramp ReadinessPartner with plant leadership to define line layouts, automation needs (winding, insertion, forming, welding, impregnation, assembly), tooling/fixtures, and test equipment.Ensure process validation (IQ/OQ/PQ), first-pass yield, takt time alignment, OEE, and throughput targets.Embed Lean and Six Sigma principles—error-proofing (Poka?Yoke), standardized work, and continuous improvement (Kaizen).4) Supply Chain & Supplier DevelopmentCo-lead make/buy strategy, should-cost modeling, and value engineering (VAVE).Qualify and develop suppliers for laminations, copper, magnets (NdFeB), die castings, machined parts, insulation systems, adhesives, and sensors.Drive supplier APQP, PPAP, VDA 6.3 audits, incoming quality planning, and dual-sourcing/risk mitigation.Negotiate engineering changes, lifecycle cost reduction, and long-lead material risk (magnets/copper).5) Quality, Safety & ComplianceOwn product quality targets (PPM, warranty, reliability, durability) and 8D/root cause culture.Ensure compliance with IATF 16949 / ISO 9001, ISO 26262 (ASIL where applicable), IEC 60034 family, UL/CE where relevant, RoHS/REACH, HV safety, and EHS requirements.Lead cross-functional change control (ECN/ECO) with robust verification/validation and traceability.Qualifications:Bachelor’s or Master’s degree in Electrical, Electronics or Computer Science Engineering.12+ years of experience in electric motor design/manufacturing, with at least 5 years in a senior leadership position within a Tier-1 supplier/OEM.Proven track record taking tractoin motors from concept to mass production at automotive scaleStrong DFM/DFA expertise: laminations, stamping, stacking, hairpin/conventional winding, welding (laser/TIG), machining, balancing, sealing and EOL testingFluency in DFMEA/PFMEA, Control Plans, APQP/PPAPQuality and Safety Systems: IATF 16949/ISO 26262, VDA 6.3, basic IEC 60034 understanding, UL/CE, RoHS/REACH, HV safety practicesDemonstrated leadership with suppliers and operations: Costing, acquisitions, VAVE, dual sourcing, launch rampExcellent communication, stakeholder management and decision making under ambiguityL&T Company Overview / About Us:L&T is a USD 30 billion Indian multinational engaged in EPC Projects, Hi-Tech Manufacturing, and Services, operating across multiple geographies. A strong, customer–focussed approach and the constant quest for top-class quality have enabled L&T to attain and sustain leadership in its major lines of business for eight decades.Given L&T’s capability in strategic electronics and leveraging its foray into semiconductor design and well-established capabilities in L&T Technology Services, the business is expanding its offerings to cover industrial electronic modules, products and systems in critical sectors of Power Electronics, Automotive Electronics, Industrial Robotics & Automation, Communication Platforms and Electronic Systems Design & Manufacturing (ESDM). The focus products under Automotive Electronics are ADAS, Electrification & Connectivity related products.