Manager /Sr. Manager – NPD (Forging Process)

Role: NPD (Forging Process)

Reports To: Head – Engineering

Qualification: B.E./B.Tech. in Mechanical / Production / Industrial Engineering.

Experience: upto 14–16 years of experience in New Product Development / Process Engineering in a forging industry (preferably automotive or heavy engineering sector). Experience in handling customer projects from development to mass production is essential.

Key Responsibilities:

1.New Product Development

• Lead the complete NPD process from enquiry, feasibility study, and cost estimation to successful PPAP and SOP.
• Study customer drawings, specifications, and technical requirements to develop process flow, forging sequence, and material selection.
• Coordinate with design, production, tool room, and quality departments for die design, tooling development, and validation.
• Plan and conduct forging trials, analyze results, and implement necessary modifications for process optimization.

2. Process & Tool Design

• Prepare and review process layouts, forging drawings, and tool designs (dies, punches, mandrels, etc.).
• Ensure proper die design considering material flow, load distribution, and forging defects prevention.
• Work closely with tool room for die manufacturing and maintenance.

3. Project Management

•    Prepare detailed project timelines and monitor progress to ensure timely completion of new product launches
• Identify risks in project execution and take corrective and preventive actions.
• Maintain project documentation including APQP, DFMEA, PFMEA, and PPAP reports.

4. Customer Coordination

• Act as a key technical interface with customers for all new development activities.
• Handle technical discussions, design approvals, and development status updates with OEMs or Tier-1 customers.

5. Quality & Validation

• Ensure dimensional accuracy, metallurgical properties, and mechanical strength as per customer specifications
• Coordinate for inspection reports, layout inspections, and metallurgical test reports during development.
• Drive continuous improvement in product design and forging process.

6. Cost & Efficiency

• Optimize process flow to achieve material yield improvement and cost reduction.
• Analyze forging load, machine capacity, and process efficiency for new components.
• Support cost estimation and quoting for new business opportunities.

7. Team Leadership

• Guide and mentor NPD engineers and cross-functional teams.
• Promote teamwork and collaboration across departments to meet project objectives.

Key Skills & Competencies:

• Strong technical knowledge of closed-die / open-die / ring rolling forging processes.
• Hands-on experience in process design, die design, and tooling development.
• Proficiency in CAD software (AutoCAD, SolidWorks, CATIA, or Unigraphics).
• Good understanding of metallurgy, heat treatment, and material flow.
• Familiarity with APQP, PPAP, FMEA, and other automotive quality systems.
• Excellent project management and problem-solving skills.
• Strong communication and coordination ability with internal teams and customers.