Job Description Summary

The Lead – Special Tool Design is responsible for the end-to-end design and delivery of lifting, handling, and assembly tools for hydro turbine and generator components. This role spans concept development, 3D modeling, detailed drawings, engineering calculations, and technical support through manufacturing, testing, and field use. The lead will guide a small team of designers/engineers, ensure compliance with applicable standards, and drive design quality, safety, and cost effectiveness.

Job Description

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

• Create and/or oversee creation of accurate 3D models of lifting and handling tools using e.g., NX / Creo / Solid Works / 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.
• Calculation approval from Expert, ensuring traceability and proper documentation.
• 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.
• Lead and mentor a team of engineers/designers, providing technical guidance and on-the-job training.
• Allocate tasks, monitor 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.)
• Typically 8+ / 10+ – adjust 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, Solid Works, 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.

Note:

To comply with US immigration and other legal requirements, it is necessary to specify the minimum number of years' experience required for any role based within the USA. For roles outside of the USA, to ensure compliance with applicable legislation, the JDs should focus on the substantive level of experience required for the role and a minimum number of years should NOT be used.

Additional Information Relocation Assistance Provided: Yes