Design for Manufacturing Engineer - Motor

Role Overview

As a Design for Manufacturing Engineer focused on motors, you will own DFM work for EV traction motors and related sub-assemblies. The role centers on turning product requirements and design intent into production-ready designs, tooling specifications, and stable, scalable manufacturing processes. You will also facilitate DFM/DFA reviews, drive PFMEA and Control Plan development, lead supplier APQP/PPAP activities, and help ensure the factory is prepared for quality, output, safety, and cost targets.

Business Unit

EPS Mobility

Core Responsibilities

• Carry out DFM/DFA analysis for stator and rotor assemblies, including laminations, stacking, interlocks, hairpin and conventional winding, forming, welding or brazing, impregnation and varnish, encapsulation, balancing, and mechanical assembly.
• Refine tolerances and GD&T to improve manufacturability and process capability, while establishing datum plans, stack-up logic, and CTQ characteristics.
• Translate design goals into requirements for tooling, fixtures, and automation across winding, insertion, forming, laser welding, machining, sealant dispensing, and end-of-line testing.
• Lead validation activities such as IQ/OQ/PQ and capability evaluations using Cp/Cpk for critical dimensional and electrical parameters.
• Work closely with Design Engineering to shape material selection, geometry, and joining approaches that support manufacturability, NVH performance, thermal behavior, and reliability.
• Coordinate with Operations and Manufacturing Engineering on line arrangement, takt time, ergonomics, poka-yoke, standard work, and OEE improvement.
• Partner with Supply Chain and SQE teams on make-versus-buy decisions, should-cost analysis, supplier DFM workshops, APQP deliverables, PPAP submissions, and incoming quality plans.
• Support definition of end-of-line test strategy covering electrical performance, partial discharge, vibration, noise, and insulation resistance.
• Develop and maintain PFMEA, Control Plans, Work Instructions, MSA plans including gage R&R, and SPC charts for high-risk features.
• Ensure alignment with IATF 16949, ISO 9001, applicable IEC 60034 test methods, RoHS, REACH, and functional safety interfaces where relevant.
• Lead root-cause investigations for yield losses, scrap, and warranty issues using methods such as 5-Why, Fishbone, and 8D, then implement corrective and preventive actions.
• Promote EHS practices for processes involving resins, solvents, lasers, high-voltage handling, and machine safety interlocks.
• Drive value engineering and design-to-cost initiatives such as improving copper fill factor, increasing lamination utilization, simplifying processes, and evaluating material substitutions.
• Reduce cycle time and changeover loss through SMED, error-proofing, and automation improvements, while monitoring FPY, scrap, and rework trends.
• Create dashboards to track capability, FPY, PPM, and PPAP progress.

Qualifications

• Bachelor’s or Master’s degree in Electrical, Electronics, or Computer Science Engineering.
• 2 to 10 years of experience in electric motor design or manufacturing.
• At least 5 years in a senior leadership role within a Tier-1 supplier or OEM environment.
• Practical exposure to motor manufacturing processes such as lamination stamping and stacking, hairpin or conventional winding, insulation systems, and laser welding.
• Working knowledge of IATF 16949, ISO 9001, and production part approval processes.
• Ability to use CAD tools such as NX, CATIA, or SolidWorks, along with Excel, Minitab, or Power BI for capability analysis and DOE.
• Strong communication, stakeholder management, and decision-making skills, especially in ambiguous situations.

Company Overview

L&T is a USD 30 billion Indian multinational with operations spanning EPC projects, hi-tech manufacturing, and services across multiple geographies. The organization is recognized for a strong customer focus and a long-standing commitment to quality, which has supported leadership across its key businesses for decades. Building on capabilities in strategic electronics, semiconductor design, L&T Technology Services, and electronic systems design and manufacturing, the business is expanding into industrial electronic modules, products, and systems in power electronics, automotive electronics, industrial robotics and automation, communication platforms, and ESDM, with a particular focus on ADAS and electrification-related automotive offerings.