Manufacturing Engineering 2

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Job Description:

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JOB Description – Manufacturing Engineer 2

Caterpillar Inc is the world’s leading manufacturer of off-highway machinery and diesel and natural gas engines. The Caterpillar brand is recognized worldwide and is synonymous with quality and reliability.

The Industrial Power Systems Division currently has a new and exciting opportunity for a Manufacturing Engineer. This position works both independently and as part of a team to maintain and improve processes and systems used in manufacturing. In addition, Manufacturing Engineers function as a specialist and subject matter expert for technical planning throughout a manufacturing facility. As Manufacturing Engineer, you will have an opportunity to provide the technical expertise necessary to design, develop, and implement manufacturing systems, manufacturing operations and state of the art machines.

JOB PURPOSE:   To provide expertise in specific areas of the manufacturing process to ensure the most efficient and cost-effective manufacture of product.

The Manufacturing Engineer with specialization in Cold Test and Leak Test of Engines will be responsible for the design, development, implementation, and optimization of testing processes within engine manufacturing. This role ensures that engine components meet stringent quality and performance standards by employing advanced cold and leak testing techniques. The individual will work closely with cross-functional teams, including production, quality, and maintenance, to drive continuous improvement in testing processes, maintain product integrity, and ensure the smooth execution of operations.

Job Duties/Responsibilities may include, but are not limited to:

This is a staff position which is expected to function as a specialist with respect to a specific technical phase of the manufacturing engineering function and which generally falls within the major areas of releasing, Engine Assembly, Test, Paint processing, assembly processing, layout, work standards and manufacturing development.

• Work assignments may be specialized in nature but may also be broad based with coordination between other staff personnel to complete a larger project.
• Incumbents evaluate projects to define desired results and determine logical approaches.
• Evaluates such factors as cost, personnel yearly usage, equipment, space, etc. as well as other information needed to determine requirements.
• Prepares feasibility studies for appropriateness and cost effectiveness and submits recommendations accordingly.
• Results contribute to the effective management decisions in determining the most efficient processes, methods, machinery, tools, equipment, services and systems needed in the manufacture of product.
• Adheres to established standards, policies and practices relating to quality, cost reduction, safety, ergonomics, etc. in performing assigned duties.

Actual work assignments may be typified as follows:

1. Cold Test Development & Implementation:

• Design & Setup: Lead the development and installation of cold test systems that simulate engine performance at ambient conditions without full combustion. This includes setting up sensor arrays to capture key performance parameters (e.g., pressure, torque, vibration, fuel injection, oil flow, and crankshaft speed).
• Test Protocols: Develop, document, and optimize cold test procedures based on specific engine models and customer requirements. This includes establishing pass/fail criteria for each critical parameter.
• Data Analysis: Analyze test results to identify engine defects, anomalies, or non-conforming behaviors. Provide recommendations to improve engine designs or manufacturing processes based on test data.
• Equipment Calibration & Maintenance: Ensure that all cold test equipment is regularly calibrated, maintained, and updated to industry standards to ensure accurate and reliable testing.
• Root Cause Analysis: Lead root cause analysis of cold test failures and collaborate with design and production teams to resolve identified issues, ensuring continuous product improvement.

2. Leak Test Development & Implementation:

• Leak Testing Technologies: Develop and implement leak detection processes for engine components such as cylinder heads, engine blocks, fuel systems, gaskets, and seals using techniques like pressure decay, vacuum, mass spectrometry, and helium leak detection.
• Tooling and Equipment Selection: Work with suppliers and internal teams to select and implement the best leak detection technologies that meet production volumes and quality standards.
• Test Cycle Optimization: Optimize leak testing cycle times to balance test accuracy and throughput. Develop strategies for quick changeover of tooling to minimize production downtime.
• Test Condition Settings: Configure testing equipment to operate at optimal conditions (e.g., test pressure levels, temperature control) to ensure precise defect detection, even for micro-leaks.
• Process Standardization: Create and enforce standardized leak test procedures, ensuring consistent application across all production lines.

3. Process Optimization:

• Continuous Improvement: Apply Six Sigma, Lean, and other process improvement methodologies to optimize both cold and leak testing processes. This includes reducing test time, enhancing test accuracy, and improving overall equipment effectiveness (OEE).
• Cycle Time Reduction: Identify bottlenecks in testing processes and introduce automation or new techniques to improve cycle time without compromising test quality.
• Defect Prevention: Use data from tests to drive design improvements and manufacturing process changes that prevent defects from occurring, such as better sealing processes, enhanced material selection, or tighter machining tolerances.

4. Equipment & Tooling Management:

• Vendor Management: Coordinate with external suppliers and technology providers for procurement, commissioning, and continuous support of testing equipment. Evaluate vendor performance based on equipment reliability and service support.
• Equipment Health Monitoring: Develop a preventive maintenance schedule for all cold test and leak test equipment to ensure minimal downtime and to avoid unplanned stoppages.
• Capacity Planning: Ensure that testing equipment is scalable and capable of handling future production volumes, especially during new product introductions or expansions.

5. Cross-Functional Collaboration:

• Interdepartmental Coordination: Collaborate with production and quality teams to integrate cold and leak testing into assembly workflows seamlessly. Ensure proper communication between departments to resolve issues quickly and efficiently.
• Training: Provide hands-on training to production and maintenance staff on the correct operation and maintenance of cold test and leak test equipment.
• Feedback Loops: Act as the point of contact between manufacturing engineering and design teams, feeding back insights from test results to improve future engine designs and manufacturing processes.

6. Quality Assurance & Compliance:

• Regulatory Standards: Ensure that testing processes adhere to all relevant industry standards (ISO, ASTM, etc.) and environmental regulations.
• Documentation & Reporting: Maintain detailed records of all test results, including test conditions, failure rates, and corrective actions taken. Generate regular reports for upper management on test effectiveness and trends.
• Audits: Participate in internal and external audits to ensure compliance with quality management systems and continuous improvement standards.

7. Project Management:

• New Product Introduction (NPI): Lead testing requirements and validation for new engine designs during the NPI phase. Collaborate with the design team to ensure testing protocols are defined early and adjusted as necessary throughout the product development process.
• Budgeting & Cost Control: Develop and manage budgets related to cold test and leak testing equipment. Identify opportunities to reduce costs by improving testing efficiency or adopting new technologies.
• Project Execution: Drive key capital investment projects for test system upgrades or new installations, ensuring timelines, cost targets, and performance objectives are met.

Projection, evaluation, specification, and acquisition of new or replacement machine tools.

• Provides engineering consultation on manufacturing processes, possible tooling and gaging requirements, and cost/delivery analysis.
• Develop and implement cost reduction programs consistent with Lean Manufacturing principals.
• Uses computerized design and computer aided engineering tools to perform job requirements.
• Proficient on materials used in the manufacturing of Tools used in Engine Assembly (Ex: Jigs & Fixtures).
• Proficient in manufacturing process of Jigs & Fixtures (Ex: Machining, Fabrication, Welding etc.).
• Analyze tooling failures and evaluate tool characteristics and requirements.
• Plan Factory layouts for effective utilization of space due to rearrangement, new processes, or expansion.
• Determining the need for modern facilities; assembly planning.
• Develop and implement assembly processes in line with CPPD (Concurrent Process and Product Development) and NPI design changes, etc.
• Transition new products from engineering to manufacturing.
• Developing, analysing and managing Manufacturing/ Assembly Projects. 
• Engaging in creative problem solving to address operational issues including ergonomic/ safety, efficiency improvements, process bottlenecks, quality concerns. 
• Manage projects to ensure efficient and cost-effective systems and processes to produce quality products. 
• Providing the application, procurement, processing, installation, and capability for new equipment. 
• Providing manufacturing technical support in process control and internal certification. 
• Coordinating the purchase and application of machine tools, controls and related equipment to ensure the latest technology is being used to increase efficiency and economy of operations. 
• Develop new production methods using lean engineering fundamentals.
• Evaluate projects and prepare feasibility studies to define desired results, assess value proposition and determine project plans.
• Improve space utilization in the shop floor.
• Develop APQP process documentation (assembly procedures, test procedures, BOMs, process flows, and process FMEAs) in conjunction with cross functional team.
• Develop and implement assembly processes in line with Caterpillar standard processes.
• Estimate production times, staffing requirements, and related costs to provide information for management decisions.

Required Qualifications:

• Bachelor's Degree in Mechanical Engineering.
• MS or MTech or Advanced Degree.
• 5 to 8 years in manufacturing engineering; including NPI experience.
• Experience in Engine Assembly Processes is a plus. 
• Experience in Cold Test & Leak Test of Engines is a plus.
• Proven experience (5+ years) in engine testing, with a focus on cold and leak testing methodologies.
• Strong knowledge of cold testing techniques and leak detection systems (e.g., mass flow, pressure decay, helium testing).
• Experience with advanced test equipment calibration, troubleshooting, and maintenance.
• Lean Manufacturing or Six Sigma certification (Green Belt/Black Belt preferred).
• Familiarity with engine assembly processes, and a deep understanding of engine component functionality and test requirements.
• Excellent problem-solving skills with the ability to analyze data and implement effective solutions.
• Strong communication and collaboration skills to work with cross-functional teams.
• Proven experience prioritizing and managing multiple responsibilities.
• Proven leadership skills with written and verbal communication skills to work internally and externally at all levels of an organization.
• Excellent interpersonal skills with the ability to collaborate well and work both independently and collaboratively in teams.
• Proficient with data collection, data analysis, root cause analysis and use of metrics.
• Experience with SAP ERP software and manufacturing execution systems (MES) is a plus.
• Advanced Microsoft Office Skills, Team Center & Virtual Build skills.
• Knowledge of mechanical and electrical manufacturing processing, including assembly and testing.

Desired Qualifications:

• Proficiency in testing automation and data acquisition systems.
• Experience with engine testing software and data analytics tools.
• Project management skills to oversee equipment installations and process improvements.
• Post Diploma in Tool Design.
• Experience in Tool Design. Designing of Jigs & Fixtures, Gauges etc.
• Experience in CREO and AutoCAD.
• Experience in complex work environments, including (but not limited to robotics, automation, special purpose machines, material handling and assembly equipment's).
• Well versed in Lean Manufacturing & Continuous Improvement principles & techniques.
• Thorough knowledge of manufacturing concepts with emphasis in engine assembly, engine testing and paint processes.
• Launch experience of Automotive or Engine Assembly.
• Experience in Electrical Controls & PLC Programming.
• Experience in Discrete Event Simulation (DES) & related concepts is preferred.
• Experience in Internet of Things (IOT) and Industry 4.0 concepts is preferred.

This Job Description is intended as a general guide to the job duties for this position and is intended for the purpose of establishing the specific salary grade. It is not designed to contain or be interpreted as an exhaustive summary of all responsibilities, duties and effort required of employees assigned to this job. At the discretion of management, this description may be changed at any time to address the evolving needs of the organization. It is expressly not intended to be a comprehensive list of “essential job functions” as that term is defined by the Americans with Disabilities Act.

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Caterpillar is an Equal Opportunity Employer (EEO).

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