AM or Manager Process Engineering and New Product Development

Role

Position: Senior Engineer / Assistant Manager Process Engineering & New Product Development

BALU FORGE INDUSTRIES LIMITED

Department: Engineering / New Product Development
Location: BFIL Forging & Machining Division
Reporting To: HOD Engineering / NPD
Qualification: Diploma / BE Mechanical Engineering
Experience: 10–15 Years in CNC/VMC/HMC Machining, Process Engineering & New Product Development

1. Job Purpose

To lead and execute process engineering and new product development activities for forging and machined components, with primary responsibility for CNC/VMC/HMC programming, process planning, tooling selection, prove-out, cycle-time optimization, quality improvement and successful transfer of new products to production.

Responsibilities

A. New Product Development

• Study customer drawings, specifications and technical requirements for new products.
• Develop operation-wise machining processes for new components.
• Select appropriate machines, machining sequences, tools, fixtures and cutting parameters.
• Prepare CNC/VMC/HMC programs for new product development.
• Conduct machine prove-out and process validation during new product development.
• Coordinate with Production, Quality, Tool Room, Maintenance and Purchase/Vendor Development teams.
• Ensure smooth transfer of new products from development to regular production.
• Support APQP, PPAP and other customer-specific requirements.

B. CNC / VMC / HMC Programming

• Develop, modify and optimize CNC programs for machining operations.
• Handle CNC controllers including Fanuc, Siemens, Hurco and Mitsubishi.
• Optimize cutting parameters, tool paths and machining sequences to improve productivity.
• Reduce machining cycle time and improve machine utilization.
• Implement standard programming practices and maintain program documentation.
• Troubleshoot programming and machining-related problems.

C. Process Engineering

• Develop and maintain operation-wise process plans.
• Identify opportunities for process improvement, cycle-time reduction and productivity enhancement.
• Reduce setup and setting-change time on CNC, VMC and HMC machines.
• Conduct process gap analysis and implement corrective actions.
• Standardize machining processes for repeat production.
• Support OEE improvement initiatives.

D. Tooling & Fixture Development

• Select appropriate cutting tools based on material, operation and machining requirements.
• Develop and optimize tool selection for different machining operations.
• Coordinate with Tool Room and tool suppliers for tooling requirements.
• Support development and improvement of jigs and fixtures.
• Implement poka-yoke concepts in fixtures and machining processes.
• Monitor tool life and optimize tooling cost.

E. Production & Productivity

• Support Production in achieving planned output as per customer requirements.
• Ensure production is achieved within specified cycle time while maintaining product quality.
• Analyze production losses, downtime, rejection and rework.
• Coordinate with Production teams for effective utilization of manpower and machines.
• Support three-shift production activities whenever required.
• Monitor OEE and identify improvement opportunities.

F. Quality Improvement

• Ensure processes are capable of consistently meeting specified quality requirements.
• Investigate machining-related rejection and rework.
• Implement corrective and preventive actions.
• Work closely with Quality Department for process improvement.
• Support implementation of IATF 16949 requirements and customer-specific quality requirements.
• Maintain required process and development documentation.

G. Vendor Development

• Support development and qualification of new machining/tooling vendors.
• Coordinate with vendors to achieve required quality, productivity and delivery performance.
• Ensure vendor output meets defined technical and quality parameters.
• Conduct technical evaluation and follow-up of vendor development activities.

H. Continuous Improvement

• Identify and implement Kaizen opportunities.
• Participate in TPM, 5S and machine improvement activities.
• Support "Tagging My Machine" and autonomous maintenance-related activities.
• Identify bottlenecks and implement productivity improvement measures.
• Drive reduction in cycle time, setup time, rejection, rework and tooling cost.

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