Mechanical Process & Manufacturing Specialist

Thales is a global technology leader trusted by governments institutions and enterprises to tackle their most demanding challenges. From quantum applications and artificial intelligence to cybersecurity and 6G innovation our solutions empower critical decisions rooted in human intelligence. Operating at the forefront of aerospace and space cybersecurity and digital identity were driven by a mission to build a future we can all trust.

Primary Purpose of the Role

Thales is expanding its presence in India through the development of a Group Engineering Competence Centre (ECC) reinforcing its position as a leader in all its markets. Launching in early 2019 in Bengaluru the ECC will expand Thales footprint in its core business areas and cement its long-standing relationship with India. Thales has an objective to expand industrial process engineering function in India ensuring remote engineering support to Thales Industry and preparing industrial footprint expansion in the region. Achieving a high level of maturity for our products in production is one of the major challenges of the Thales industry both during the industrialization phase and throughout the products life cycle.

This Job Description is for Industrial Process Engineering & the Role is MECHANICAL PROCESS & MANUFACTURING SPECIALIST
The role is based in Bangalore and requires frequent travel to supplier sites across Bangalore and other locations within India and Asia.

Organization
You will be part of the Industrial Process Engineering Industrialization team responsible for defining and managing manufacturing technologies for electronic boards mechanical components and related processes. The team supports all product life-cycle phases bidding development and series production. Key Responsibilities and Tasks
Core Responsibilities
Responsible for co-developing qualifying optimizing Mechanical Manufacturing & Assembly processes with Suppliers
Work closely with suppliers to ensure adherence to approved manufacturing processes specifications and quality requirements - Serve as the primary technical point of contact for manufacturing processes with suppliers.
Review challenge and validate supplier process documentation (process flows control plans PFMEA work instructions) and ensure compliance with standards customer and internal guidelines.
Support resolution of manufacturing and quality issues during development and series production including participation in supplier audits and on-site technical reviews.
Drive continuous improvement initiatives with suppliers including cost quality lead-time optimization supplier qualification and standardization of best practices across the supply base.
Manage process evolution and technology upgrades.

NPI Activities (working with industrial architects and engineering teams)
Support New Product Introduction (NPI) and industrialization activities at supplier sites in following phases:
R& T Phase:
oCollaborate with R&T teams to support industrialization activities(POC Mock up) Manufacturing Readiness Level (MRL) maturity plans and the introduction of emerging mfg. technologies materials and processes.
Bidding Phase:
oEvaluate and recommend manufacturing processes based on risk assessments and supplier capability process maturity including technical support during supplier selection.
Development Phase:
oDevelop execute and approve process qualification and APQP plans to confirm manufacturing readiness including tooling materials and equipment capability.
oConduct DFM/DFA reviews with internal design teams and suppliers and propose design optimizations to achieve target cost and manufacturability objectives.
oLead supplier industrial reviews such as Production Readiness Reviews (PRR) and First Article Inspections (FAI).
oSupport or lead run-at-supplier (pilot line / proto) trials to validate joining process feasibility.
oEnsure suppliers conduct proper capability studies (Cp Cpk) & validate
oSupport supplier in implementing process monitoring systems (e.g. force-displacement curves camera vision systems).
oAssist supplier in equipment selection and approval to ensure compliance with process performance targets.
oWork with suppliers to ensure tooling jigs and fixtures are robust and durable for operation.

Transfer & Series Production Activities (in coordination with Series Product Managers Supplier Product Quality Managers and Industrial Transfer Managers)
Support BTP (Build To Print) transfer by ensuring the supplier achieve technical capability (mastering of technological processes before transfer)
Provide technological support for production including defect analysis and expert intervention.
Lead root cause analysis and drive corrective actions for manufacturing or assembly issues.
Manage risk assessments and mitigation strategies throughout the project lifecycle.
Manage process evolution and technology upgrades with subcontractors and relevant stakeholders

Cross-Functional Missions
Develop and update technical standards within the Mechanical domain; participate in Thales Group-wide working groups.
Suggest process and business tool improvements to enhance efficiency and quality.
Maintain adherence to aerospace quality standards including ISO and EN 9100
Work closely with the France team to understand and benchmark processes then collaborate with suppliers to implement and qualify those processes.

Major Challenges
Ensure Supplier Quality Process Development meets global industrial plan & Timeline
Work with multiple GBUs/BLs of France in a different Time Zone
Work with multiple Suppliers/multiple projects in tandem for Process Qualification
Continuously Develop the required technical skills (skilling-up) and capability by effective learning Opportunities
Opportunity to work in an organization driving the development of a structured engineering footprint aligned with Thales growth and competitiveness ambitions.
Opportunity to collaborate with colleagues from diverse cultural backgrounds across the globe
A work environment that fosters professional development through continuous learning close team collaboration and a solution-oriented mindset. Skills & Knowledge Required Technology

Skills
Strong Knowledge of precision mechanical manufacturing and assembly technologies:
o Mandatory 5 Axis machining Turning Milling Riveting Clinching Screwing Press Fitting.
o Nice to Have EDM Heat treatment Brazing Gluing Casting Forging
Nice to Have - Knowledge on Surface Treatment - Aluminum Corrosion protection Chemical Conversion-Surtec Anodization & Metal Plating (Ni Silver Zinc) Painting
Knowledge of expertise techniques and methods: SEM X-rays micro-sectioning destructive analyses
Proficiency in reading engineering drawings GD&T and tolerance stack-up analysis
Hands-on experience with process validation SPC and Measurement Tools usage
Experience with lean manufacturing principles including 5S Kaizen and value stream mapping.
Competency in process optimization to improve cycle time reduce waste and enhance throughput.
Knowledge of safety standards and ergonomics in manufacturing environments.

Software/Tools:
CAD software (CREO AutoCAD) Quality Tools
Hands on of APQP (Advanced Product Quality Planning) methodology & documentation.
Experienced in root cause analysis and problem-solving techniques (PDCA 8D 5 Whys Fishbone)

Soft Skills
Learning & Proactive mindset with a continuous focus on improvement.
Strong analytical communication interpersonal and problem-solving abilities.
Dynamic and flexible able to adapt to changing priorities.
Analytical thinker with strong problem-solving skills and logical reasoning.
Detail-oriented with a focus on quality and continuous improvement.
Ability to work independently and manage multiple priorities.

Years of experience Required
8 to 10 years of experience in precision part manufacturing and assembly including NPI and series production in In House & outsourced environments.
Experience in the aerospace sector is preferred.

Educational Qualification Required
Bachelor/Masters in Mechanical Engineering

Language English French basic knowledge is a plus

At Thales were committed to fostering a workplace where respect trust collaboration and passion drive everything we do. Here youll feel empowered to bring your best self thrive in a supportive culture and love the work you do. Join us and be part of a team reimagining technology to create solutions that truly make a difference for a safer greener and more inclusive world.