Career Area:

Manufacturing

Job Description:

Your Work Shapes the World at Caterpillar Inc.

When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other.  We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it.

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:

•            Cold Test Development & Implementation:

o            Design and implement cold test processes for engine validation, ensuring adherence to performance and safety & quality specifications.

o            Develop and calibrate cold test equipment to measure parameters such as pressure, torque, and noise, ensuring optimal engine performance without a full engine run.

o            Collaborate with product engineering teams to define cold test criteria for new engines and validate production standards.

•            Leak Test Development & Implementation:

o            Lead the development and optimization of leak testing processes to ensure the integrity of engine components such as cylinder heads, engine blocks, and fuel systems.

o            Develop test protocols, configure testing equipment, and ensure compliance with industry standards for leak testing.

o            Troubleshoot and resolve issues related to leak detection methods such as pressure decay, mass spectrometry, or helium leak testing.

•            Process Optimization:

o            Analyze test data and provide feedback on performance improvements to product design and manufacturing processes.

o            Continuously improve cold and leak test methodologies to reduce cycle times, enhance accuracy, and increase equipment reliability.

o            Utilize Lean and Six Sigma methodologies to streamline test processes and reduce waste in the testing operations.

•            Equipment & Tooling Management:

o            Select, configure, and maintain testing equipment and tooling, ensuring they meet production capacity and quality standards.

o            Coordinate with equipment suppliers for the procurement, installation, and commissioning of cold and leak testing equipment.

•            Cross-functional Collaboration:

o            Collaborate with production, quality, and maintenance teams to integrate testing procedures into manufacturing workflows.

o            Provide technical expertise and training to production teams on testing procedures and equipment operation.

•            Quality Assurance & Compliance:

o            Ensure that testing processes align with regulatory requirements, industry standards, and customer specifications.

o            Conduct regular audits of test systems and procedures to maintain high-quality standards and adherence to safety protocols.

•            Continuous Improvement:

o            Lead continuous improvement initiatives to enhance testing accuracy, reduce test time, and lower operational costs.

o            Track and analyze key performance indicators (KPIs) to identify opportunities for improvement in testing efficiency and effectiveness.

•            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, analyzing 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.

Relocation is available for this position.

Posting Dates:

April 16, 2025 - April 29, 2025

Caterpillar is an Equal Opportunity Employer (EEO).

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