Machine Shop Manager

Job Summary

We are looking for an experienced Machine Shop NPD Manager with strong hands-on knowledge of machining processes, CNC/VMC/HMC turning, milling, grinding, tooling, fixtures, process planning, and new product development.

The person will be responsible for end-to-end NPD activities from drawing study and feasibility to process development, trials, PPAP, and successful production handover, while ensuring quality, cost, productivity, and delivery targets.

Experience: 8-10 years

Key Responsibilities

• Lead New Product Development (NPD) activities for machined components from RFQ/drawing review through production launch.
• Study customer drawings, specifications, GD&T, material requirements, tolerances, surface finish, and special characteristics.
• Conduct manufacturing feasibility and identify machining challenges, risks, and cost-reduction opportunities.
• Develop complete machining process plans, process flow, operation sequences, and cycle-time estimates.
• Strong knowledge of CNC turning, VMC, HMC, drilling, boring, tapping, broaching, grinding, honing, and other precision machining processes.
• Develop and optimize CNC programs, cutting parameters, tool selection, tool-life studies, and machining strategies.
• Select appropriate cutting tools, inserts, holders, drills, reamers, taps, and special tools.
• Design/develop jigs, fixtures, soft jaws, checking fixtures, and poka-yoke solutions in coordination with tooling teams.
• Plan and execute machine trials, prove-outs, first-off inspection, capability studies, and process validation.
• Drive APQP, PFMEA, Control Plan, Process Flow, MSA, SPC, PPAP and Run-at-Rate activities.
• Coordinate with Quality, Production, Tool Room, Purchase, Maintenance, Design, and Sales/Program Management teams.
• Monitor and improve cycle time, OEE, tool consumption, rejection, rework, and machining cost.
• Identify opportunities for process optimization, automation, line balancing, and productivity improvement.
• Support root-cause analysis and corrective actions for machining-related quality issues.
• Ensure successful transfer of developed products from NPD to regular production.
• Manage multiple NPD projects and ensure timely completion against project milestones.
• Develop and maintain process documentation, work instructions, setup sheets, tool lists, and technical standards.

Technical Skills Required

• Strong knowledge of CNC/VMC/HMC machining processes.
• CNC turning and milling process knowledge.
• Understanding of cutting parameters: speed, feed, depth of cut, tool geometry and tool life.
• Knowledge of carbide inserts, PCD/CBN tools and special tooling.
• Strong understanding of GD&T, tolerance stack-up, datum systems and drawing interpretation.
• Knowledge of jigs, fixtures, workholding and clamping principles.
• Knowledge of machining of steel, cast iron, aluminium, stainless steel and alloy materials.
• Understanding of surface finish, roundness, cylindricity, concentricity, runout and dimensional capability.
• Knowledge of CMM, height gauge, bore gauge, air gauge, micrometers, verniers and other inspection methods.
• Familiarity with CNC programming / G-code / M-code and CAM software will be an advantage.
• Knowledge of Lean Manufacturing, Kaizen, 5S, TPM and continuous improvement.
• Understanding of PPAP, APQP, PFMEA, Control Plan, SPC and MSA.

Managerial Responsibilities:

• Lead and mentor the NPD/Process Engineering team.
• Allocate NPD projects and monitor project timelines.
• Coordinate with customers and internal teams for technical clarification.
• Review and approve process plans, tooling concepts and machining feasibility.
• Track NPD project cost, timing, quality and productivity.
• Develop and implement standard machining practices across the shop.
• Drive continuous improvement and cost-reduction initiatives.