Engineer - Tooling

Key Responsibilities

1. Concept Development & Engineering

• Develop tool concepts for lifting, handling, assembly, and maintenance of hydro turbine and generator components (e.g., runner, shaft, rotor, stator, poles, covers, etc.).
• Analyze customer / project requirements, site constraints, and interface data to define tool functional requirements and boundary conditions.
• Prepare concept layouts, sketches, and simplified models to evaluate feasibility, ergonomics, and safety.
• Lead technical reviews to compare design alternatives for safety, manufacturability, cost, and schedule impact.
• Coordinate with installation, service, manufacturing, and project teams to validate concepts and collect feedback.

2. 3D Modeling & Digital Mock-Up

• Creation of accurate 3D models of lifting and handling tools using [e.g., NX / Creo / SolidWorks / Inventor / CATIA – customize as needed].
• Integrate tools into turbine/generator 3D assemblies to verify clearances, interfaces, and handling sequences (DMU checks).
• Manage parametric models to allow reuse and customization of existing tool designs.
• Maintain CAD standards, model quality, naming conventions, and data structure in the PLM system.

3. Detail Drawing & Documentation

• Generate and review manufacturing drawings for components and assemblies, including:
  • Dimensions, tolerances (GD&T as relevant)
  • Welding details, machining notes, and surface treatments
  • Bill of Materials (BOM)
  • Assembly and installation drawings
• Ensure drawings comply with internal standards and relevant international standards (e.g., ISO, ASME, DIN, EN).
• Prepare user documentation (e.g., operating instructions, lifting plans, inspection and maintenance guidelines) in collaboration with HSE and field teams.

4. Engineering Calculations & Verification

• Perform structural calculations for lifting and handling tools, including:
  • Static strength and stiffness
  • Local stresses in critical areas (lifting lugs, welds, pins, hooks, etc.)
  • Stability checks (center of gravity, tipping, overturning)
  • Fatigue assessment where applicable
• Apply relevant design codes and standards for lifting equipment and below-the-hook devices (e.g., EN 13155, ASME B30/BTH, local regulations – adjust to your context).
• Use hand calculations and/or CAE tools (e.g., FEA) to validate design integrity and safety factors.
• Support risk assessments (FMEA, hazard analysis, etc.) for special tools.

5. Project & Team Leadership

• Plan and prioritize tool design activities according to project schedules and resource availability.
• Be a team player, providing technical guidance and on-the-job training.
• Report the progress, and ensure timely delivery of design packages (concepts, models, drawings, calculations).
• Conduct design reviews and ensure that design decisions are documented and communicated.
• Collaborate with procurement, suppliers, manufacturing, and quality to resolve technical issues and optimize designs for fabrication and assembly.
• Drive continuous improvement in design methods, standards, and reusable design solutions.

6. Interface Management & Support

• Serve as the primary technical contact for special tools within projects (internal and external stakeholders).
• Support manufacturing, assembly, and site teams during tool fabrication, testing, and first-time use.
• Participate in troubleshooting and root-cause analysis for any issues in the field, proposing design improvements.
• Contribute to standardization of recurring tools and tool families for turbines and generators.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Design Engineering, or related field.
  (Master’s degree is a plus.)
• 5+ years of experience in mechanical design, including:
  • Significant experience with lifting, handling, or assembly tooling, preferably for large rotating machines, heavy equipment, or power generation.
• Strong proficiency in at least one major 3D CAD system (e.g., NX, Creo, SolidWorks, Inventor, CATIA).
• Solid experience in preparing detailed manufacturing drawings, including GD&T and BOMs.
• Demonstrated capability in performing and documenting engineering calculations for structural components (hand calculations and/or FEA).
• Familiarity with codes and standards relevant to lifting devices and mechanical structures (e.g., EN 13155, ASME standards, Eurocodes, or similar – adapt to your region).
• Experience working within a PLM system (e.g., Teamcenter, Windchill, SAP PLM, etc.) is an advantage.

Key Skills & Competencies

• Strong understanding of:
  • Steel structures, weld design, bolted joints, pins, lifting points, and rigging concepts
  • Manufacturing processes: machining, welding, fabrication, and assembly
• Ability to translate functional requirements into robust, practical mechanical designs.
• Analytical mindset with attention to detail and a strong focus on safety and reliability.
• Effective communication skills: capable of explaining technical topics to non-specialists (project managers, site teams, suppliers).
• Leadership and mentoring ability; comfortable guiding less-experienced engineers/designers.
• Proactive, solution-oriented, able to work independently and in cross-functional teams.
• Fluent in [English / local language]; additional languages are a plus for global projects.

Preferred / Nice-to-Have

• Experience in hydro power equipment (turbines, generators) or large rotating machinery.
• Knowledge of rigging plans, lifting studies, and collaboration with crane vendors.
• Hands-on exposure to site installation or service activities.
• Experience with FEA tools (e.g., ANSYS, Abaqus, Nastran) for structural analysis.
• Exposure to risk assessment methods (FMEA, HAZOP, etc.).
• Previous experience in a lead or senior design role.

Performance Indicators

• Quality and safety of delivered tool designs (no failures or major rework in field use).
• On-time delivery of design packages relative to project milestones.
• Compliance with standards and internal design rules.
• Level of standardization and reuse of tools across projects.
• Team development and effective knowledge sharing.

Relocation Assistance Provided: Yes