Deputy Manager - DT Assembly

Responsibilities & Key Deliverables

Job Purpose

The incumbent will be responsible to manage the manufacturing operations of the EV Drive Train Assembly Line, comprising Traction Motor Assembly, Intermediate Gear Assembly, Output Gear Assembly, Gearbox Integration, and Final Drive Unit Assembly. The role is responsible for achieving production targets while ensuring quality, safety, productivity, cost efficiency, and process compliance. The incumbent will drive continuous improvement initiatives and support new product introductions in a high-volume EV manufacturing environment.

Key Responsibilities

• Manage end-to-end EV Drive Train Assembly operations including motor assembly, rotor-stator assembly, gearbox assembly, intermediate gear assembly, output gear assembly, and final drive unit integration.
• Ensure achievement of daily, weekly, and monthly production targets.
• Drive productivity improvements through line balancing, cycle time reduction, and bottleneck elimination.
• Monitor and improve key manufacturing KPIs including OEE, FPY, throughput, and line efficiency.
• Ensure critical process controls related to bearing fitment, gear meshing, backlash setting, torque tightening, and lubrication.
• Lead root cause analysis and corrective actions for assembly defects and field issues.
• Drive implementation of Lean Manufacturing, TPM, Kaizen, Poka-Yoke, and 5S initiatives.
• Coordinate with Design, Quality, Supply Chain, Manufacturing Engineering, Maintenance, and Testing teams.
• Support NPI activities, pilot builds, process validation, and production ramp-up.
• Ensure operator skill development, certification, and adherence to standard work practices.
• Manage process audits, layered audits, and compliance with automotive standards.
• Ensure calibration and uptime of assembly fixtures, torque tools, presses, and testing equipment.

Key Deliverables

• Production Target Achievement
• OEE Improvement
• First Pass Yield (FPY)
• Line Efficiency Improvement
• Reduction in Assembly Defects
• Reduction in Rework and Warranty Issues
• Productivity Enhancement
• Cost Reduction Projects
• On-Time Delivery Performance
• Safety and Process Compliance
• NPI Production Readiness
• Machine and Equipment Availability

Experience

7 to 12 yrs.

Industry Preferred

Qualifications

B.E./B.Tech in Mechanical, Automobile, Production or equivalent.

General Requirements

EV Drivetrain Knowledge

• Knowledge of EV Drive Unit and Powertrain Systems.
• Understanding of Traction Motors (PMSM, Induction Motors).
• Knowledge of Rotor, Stator, Shaft and Bearing Assembly Processes.
• Understanding of Intermediate Gear Assembly and Output Gear Assembly.
• Knowledge of Gearbox Integration and Final Drive Assembly.
• Understanding of Gear Ratios, Gear Train Functionality, and Torque Transmission.
• Knowledge of Lubrication Systems and Gearbox Oil Filling Processes.
• Exposure to Dynamometer and Functional Testing of Drive Units.

Manufacturing & Assembly Processes

• Precision Mechanical Assembly Processes.
• Press Fit, Shrink Fit and Bearing Assembly Techniques.
• Torque Control and Traceability Systems.
• Line Balancing and Capacity Planning.
• OEE, Productivity and Throughput Improvement.
• Work Study and Industrial Engineering Concepts.
• Automated and Semi-Automated Assembly Systems.

Quality & Problem Solving

• PFMEA, Control Plan and SOP Development.
• APQP, PPAP, SPC and MSA.
• 7 QC Tools, Fishbone Analysis, Why-Why Analysis and 8D.
• GD&T Interpretation and Engineering Drawings.
• Gear Noise, Vibration and Harshness (NVH) Awareness.
• Root Cause Analysis and Corrective Action Implementation.

Systems & Standards

• SAP / ERP Knowledge.
• MES and Traceability Systems.
• IATF 16949 Requirements.
• ISO 9001, ISO 14001 and ISO 45001 Standards.
• Layered Process Audits (LPA).
• EHS Compliance and Safe Manufacturing Practices.

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