Asst. Manager - Engineering & NPI

JOB DESCRIPTION:Tool Design & New Product Development

Position Requirements: To lead and support tool design and new product development activities for precision machined automotive components, ensuring successful execution from RFQ and feasibility assessment through manufacturing process planning, tooling and fixture development, prototype trials, process validation, customer approval requirements, and successful transition to serial production.

Educational Qualification

B.E./B.Tech in Mechanical Engineering, or

Diploma in Mechanical Engineering

Additional certification or training in Tool Design, CAD/CAM, SOLID WORKS , CNC Machining, GD&T, or Automotive Quality Systems will be an added advantage.

Work Experience

5 to 12 years of relevant experience in precision machining, tool design, fixture development, and new product development, preferably in the Automotive or Auto Component industry.

The candidate should have hands-on experience in:

• CNC Turning, VMC, and other precision machining processes.
• Development of precision machined components from concept to serial production.
• Design and development of jigs, fixtures, work-holding systems, special tools, and inspection gauges.
• Manufacturing process planning, machining process optimization, and tooling selection.
• Prototype/sample development, machining trials, process prove-out, and validation.
• Coordination with internal teams and external tooling, fixture, and machining suppliers.
• Automotive new product development processes and quality documentation.

Preferred Industry Background
Automotive / Auto Components / Precision Machining / CNC Machining / Engineering Manufacturing.

Key Responsibilities

• Review customer drawings, technical specifications, RFQs, and customer-specific requirements to assess manufacturability, technical feasibility, process capability, and tooling requirements.
• Develop optimum manufacturing processes, operation sequences, and machining concepts for precision machined automotive components.
• Design and develop jigs, fixtures, work-holding systems, special purpose tooling, cutting tool concepts, inspection fixtures, and gauges.
• Establish appropriate locating, clamping, and work-holding methods to ensure component accuracy, repeatability, productivity, and operator safety.
• Prepare and maintain process flow diagrams, operation sheets, tooling layouts, setup instructions, and other technical documentation required for product development.
• Support the development of prototypes and samples, including CNC machining trials, tooling trials, process prove-out, and validation activities.
• Work closely with CNC Programming and Manufacturing teams to optimize machining parameters, cutting tools, cycle times, tool life, and process capability.
• Identify and implement opportunities for cycle-time reduction, productivity improvement, manufacturing cost reduction, and quality enhancement.
• Coordinate with Production, Quality, Purchase, Suppliers, and other cross-functional teams to achieve development milestones and project timelines.
• Coordinate with external tooling and fixture suppliers for design review, manufacturing, trials, modifications, validation, and timely delivery of tooling.
• Troubleshoot machining, tooling, fixture, work-holding, and process-related issues during prototype development, trial production, and production ramp-up.
• Ensure that all tools, fixtures, gauges, processes, and inspection methods are validated and ready before SOP/serial production.
• Support preparation and review of PFMEA, Process Flow Diagrams, Control Plans, work instructions, and other process development documentation.
• Support APQP and PPAP activities and ensure that all product and process development deliverables meet internal and customer requirements.
• Participate in design and process reviews to identify potential manufacturing risks at an early stage and implement appropriate corrective actions.
• Support continuous improvement and standardization of tooling, fixtures, machining processes, and development practices.
• Ensure compliance with applicable automotive quality systems, engineering standards, customer requirements, and internal procedures.

Technical Competency

The candidate should possess strong technical knowledge and practical experience in the following areas:

• CNC Turning, VMC, and precision machining processes.
• Tool design and development for precision machined components.
• Design of jigs, fixtures, work-holding systems, clamping arrangements, and locating principles.
• Selection and application of cutting tools, inserts, tool holders, and machining parameters.
• Optimization of spindle speed, feed, depth of cut, cycle time, and tool life.
• Manufacturing process planning and development of optimum machining operation sequences.
• Ability to read, interpret, and analyze engineering drawings and technical specifications.
• Good knowledge of GD&T, dimensional tolerances, fits, surface finish, datum concepts, and tolerance stack-up.
• Proficiency in CAD software such as AutoCAD, SolidWorks.
• Working knowledge of CNC programming and machining simulation will be an added advantage.
• Understanding of inspection methods, gauges, CMM requirements, and measurement techniques for precision components.
• Ability to analyze and resolve machining and process-related problems using structured problem-solving methodologies.
• Knowledge of 5 Why Analysis, Fishbone Diagram, 8D, Pareto Analysis, and other root-cause analysis tools.
• Strong analytical ability, project coordination skills, and effective cross-functional communication.

Preferred Standards and Knowledge

The candidate should preferably have working knowledge of the following automotive quality systems, standards, and core tools:

• IATF 16949 - Automotive Quality Management System.
• APQP - Advanced Product Quality Planning.
• PPAP - Production Part Approval Process.
• PFMEA - Process Failure Mode and Effects Analysis.

MSA - Measurement System Analysis.

• SPC - Statistical Process Control.
• GD&T standards and engineering drawing interpretation.
• Relevant ISO standards applicable to precision machined automotive components.