Senior Engineer - NPD

Role & responsibilities

New Product Development (NPD)

• Lead the development of new plastic injection-moulded components from concept to production.
• Study customer drawings, specifications, 3D models, and product requirements.
• Review product design for mouldability, manufacturability, and cost effectiveness.
• Coordinate with Design, Tool Room, Production, Quality, and Purchase teams during NPD activities.
• Prepare and monitor NPD project timelines and ensure timely completion.

2. Injection Mould Development

• Review mould designs and provide inputs related to parting line, gating, runner system, cooling, ejection, slides, lifters, and inserts.
• Coordinate with tool room/vendors for mould manufacturing and modifications.
• Monitor mould trials and identify issues such as:
• Short moulding
• Flash
• Sink marks
• Warpage
• Weld lines
• Burn marks
• Dimensional variation
• Ensure mould modifications are completed based on trial results.

3. Trial & Process Development

• Plan and conduct T0, T1, T2 and subsequent mould trials.
• Establish suitable injection moulding process parameters.
• Analyze trial results and implement corrective actions.
• Optimize cycle time, material consumption, and machine parameters.
• Support production during the initial stages of new product launch.

4. Product & Process Validation

• Ensure dimensional and functional requirements are achieved during development.
• Coordinate for FAI, PPAP, APQP, capability studies, and validation activities, as applicable.
• Prepare and maintain NPD-related documents and reports.
• Ensure customer-specific requirements are properly implemented.

5. Problem Solving

• Identify root causes of moulding and product-related problems using 5 Why, Fishbone, 8D, and other problem-solving techniques.
• Coordinate corrective and preventive actions with relevant departments.
• Handle development-related rejection and process issues.

6. Cross-Functional Coordination

• Coordinate closely with:
• Tool Room
• Injection Moulding Production
• Quality
• Product Design
• Maintenance
• Purchase
• Suppliers/Vendors
• Customer teams
• Conduct development meetings and provide regular project status updates to management.

7. Cost & Productivity

• Identify opportunities for mould cost reduction, cycle-time reduction, material optimization, and process improvement.
• Support make-or-buy decisions and vendor development.
• Ensure NPD projects meet targeted cost and quality requirements.

8. Documentation

• Maintain:
• NPD project tracker
• Trial reports
• Mould modification reports
• Process parameter sheets
• Inspection reports
• PPAP documents
• Customer approval records
• Development history
• Maintain proper records of mould and product changes.

9. Team & Project Leadership

• Lead junior engineers and technicians involved in NPD activities.
• Allocate development activities and monitor progress.
• Ensure projects are completed within the agreed quality, cost, and delivery (QCD) targets.

Preferred candidate profile

Knowledge of APQP, PPAP, FMEA, MSA, SPC and 8D is preferred.