Design for Manufacturing Engineer - Electric Vehicle Motor

Design for Manufacturing Engineer - Motor

Business Unit: EPS Mobility

Role: Design for Manufacturing Engineer - Motor

The Design for Manufacturing Engineer will be responsible for DFM activities for EV Traction Motors and sub-assemblies and translating product requirements and design intent into production?ready designs, tooling specs, and robust, capable processes. You will run DFM/DFA reviews, lead PFMEA/Control Plan creation, drive supplier APQP/PPAP, and ensure factory readiness for yield, throughput, safety, and cost.

Key Responsibilities

DFM/DFA & Industrialization

• Perform DFM/DFA on stator and rotor assemblies: laminations, stacking, interlocks; hairpin and conventional winding; forming, welding/brazing, impregnation/varnish, encapsulation, balancing, and mechanical assembly.
• Optimize tolerances & GD&T for manufacturability and process capability; define datum strategy, stack?up, and critical to quality (CTQ) features.
• Convert design intent into tooling/fixture and automation requirements (winding, insertion, forming, laser welds, machining, sealant dispensing, EOL testing).
• Lead process validation (IQ/OQ/PQ) and capability studies (Cp/Cpk) for key dimensions and electrical parameters.

Cross?Functional Interface

• Partner with Design Engineering to influence materials, geometry, and joining methods for manufacturability, NVH, thermal performance, and reliability.
• Work with Operations/ME on line layout, takt time, ergonomics, Poka?Yoke, standard work, and OEE improvement.
• Collaborate with Supply Chain/SQE on make?buy, should?cost, supplier DFM workshops, APQP deliverables, PPAP, and incoming quality plans.
• Support EOL test strategy definition (electrical performance, partial discharge, vibration, noise, insulation resistance).

Quality, Safety & Compliance

• Create and maintain PFMEA, Control Plans, Work Instructions, MSA plans (gage R&R), and SPC charts for high?risk features.
• Ensure compliance with IATF 16949/ISO 9001, relevant IEC 60034 test methods, RoHS/REACH, and functional safety interfaces (with system safety/ISO 26262 teams as applicable).
• Drive root cause analysis (5?Why, Fishbone, 8D) for yield, scrap, and warranty issues; implement robust corrective and preventive actions.
• Champion EHS in processes (resins, solvents, lasers, high?voltage handling) and machine safety interlocks.

Cost, Yield & Throughput

• Conduct VAVE and design?to?cost activities (copper fill factor, lamination utilization, process simplification, material substitutions).
• Reduce cycle time and changeover through SMED, error?proofing, and automation refinement; track FPY, scrap, and rework trends.
• Build control dashboards for capability (Cp/Cpk), FPY, PPM, and PPAP status.

Qualifications: 

• Bachelor’s or Master’s degree in Electrical, Electronics or Computer Science Engineering.
• 2-10 years of experience in electric motor design/manufacturing, with at least 5 years in a senior leadership position within a Tier-1 supplier/OEM.
• Hands-on experience with motor manufacturing processes: lamination stamping/stacking, hairpin/conventional winding, insulation systems, laser welding etc.
• Familiarity with IATF 16949/ISO 9001 systems and production part approval
• Proficiency with CAD (NX/CATIA/Solidworks) and data tools (Excel/Minitab/Power BI) for capability and DOE analysis
• Excellent communication, stakeholder management and decision making under ambiguity

L&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.