Job Purpose (Significance of the Role & Objectives)
As the BIW (Body-in-White) Industrialization / Manufacturing Engineering Lead, you will be responsible for leading the end-to-end industrialization of BIW structures from prototype builds to SOP (Start of Production). The role focuses on establishing robust, scalable, and cost-effective manufacturing systems while ensuring quality, safety, dimensional integrity, and production readiness.
You will lead manufacturing engineering activities related to BIW assembly processes, welding technologies, tooling development, line setup, and vendor industrialization. The role is critical in ensuring successful launch execution, achieving takt time targets, and delivering production-capable BIW systems under aggressive timelines.
Key Responsibilities and Deliverables
Lead industrialization activities for BIW assemblies from prototype stage through pilot builds to SOP.
Define and implement manufacturing processes for BIW structures including welding, assembly, joining, and inspection processes.
Establish production lines, workstation layouts, equipment planning, and material flow strategies for optimal manufacturing efficiency.
Drive line setup, commissioning, and ramp-up activities to achieve targeted takt time and production capacity.
Lead development and validation of BIW tooling, welding fixtures, checking fixtures, grippers, and assembly stations.
Work closely with tooling vendors, automation suppliers, and integrators for successful execution and delivery.
Conduct process capability studies (Cp/Cpk), weld trials, and dimensional validation activities.
Ensure manufacturing feasibility through GD&T interpretation and tolerance stack-up analysis.
Review engineering changes and support DFM/DFA improvements for BIW manufacturability.
Lead APQP activities including PFMEA, Control Plans, Process Flow Diagrams, MSA, and PPAP submissions.
Lead and mentor manufacturing engineering teams, production engineers, and project stakeholders.
Participate in cross-functional team (CFT) activities for New Product Introduction (NPI), reviewing phase-wise activity matrices, and confirming manufacturing readiness.
Desired Qualifications: Required Qualification, Knowledge, and Experience
8–12 years of relevant experience in automotive BIW manufacturing or industrialization roles.
Successfully scaled BIW or automotive body structures from prototype builds to SOP.
Hands-on experience in vendor development for tooling, fixtures, welding lines, and automation systems.
Strong experience with PPAP, APQP, PFMEA, Control Plans, and manufacturing quality systems.
Proven capability in production line setup, commissioning, and takt time achievement.
Advanced expertise in GD&T and tolerance stack-up analysis for manufacturability.
Experience in weld process validation including spot welding, MIG welding, laser welding, or similar joining technologies.
Bachelor’s or Master’s degree in Mechanical, Automobile, Manufacturing, or Industrial Engineering.
Strong exposure to BIW assembly systems, welding technologies, tooling, and production engineering.
Experience with automated and manual assembly/welding lines.
Proficiency in CAD tools, technical drawings, manufacturing documentation, and process planning.
Knowledge of industrial safety standards, ergonomic studies, and lean manufacturing practices.
Key Competencies
Result oriented/Goal driven.
Manufacturing Leadership
High Accountability & Delivery Orientation
Program & Project Management
Team Mentoring & Capability Building
Highest level of integrity (teamwork, confidentiality, ethics, and integrity are the pre-requisite for the role).
Sense of ownership and pride in his/her performance and its impact on the company’s success.
