NPD-Machining Process

Role: NPD- Machining Process

Reports To: Head – Engineering

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

Experience: 14–16 years of experience in NPD and machining process development within the forging or automotive component manufacturing industry. Hands-on experience in machining development of forged or precision automotive components.

Key Responsibilities:

1. New Product Development

• Lead the end-to-end development of machined forgings based on customer requirements and technical drawings.
• Review customer specifications, feasibility, and machining requirements for new components.
• Develop process flow, control plans, and machining process sheets (PFD, PFMEA, SOP, etc.).
• Coordinate with the design, tooling, and forging teams for die design, raw forging feasibility, and machining allowances.
• Plan and execute PPAP activities and ensure timely submission of PPAP documentation.

2. Machining Process Design & Optimization

• Develop and validate machining processes, cutting parameters, and cycle times for CNC/VMC/turning centers.
• Optimize machining operations for productivity, tool life, and cost reduction.
• Select appropriate cutting tools, jigs, and fixtures for efficient machining operations.
• Monitor machining trials, analyze results, and implement continuous improvements.

3. Project Management

• Prepare and maintain project timelines, cost estimates, and progress reports.
• Coordinate with cross-functional teams (Forging, Tool Room, Quality, Maintenance, Purchase) to ensure timely project execution.
• Track and resolve technical issues during prototype and pre-production stages.
• Manage customer interactions for technical discussions, approvals, and feedback.

4. Quality & Documentation

• Ensure development and adherence to APQP, PPAP, and IATF 16949 requirements.
• Maintain documentation related to process validation, trials, and customer approvals.
• Work with the Quality team to analyze non-conformities and implement corrective actions.

5. Team Leadership & Coordination

• Lead and mentor engineers involved in NPD and machining process development.
• Develop technical competency within the team.
• Coordinate with suppliers for machining subcontracting and tooling requirements.

Key Skills & Competencies:

• Strong knowledge of machining processes (CNC, VMC, Turning, Grinding, Drilling, etc.
• Hands-on experience in process design, cycle time calculation, and tooling selection
• Good understanding of forging processes and machining allowances.
• Familiarity with CAD/CAM software (e.g., AutoCAD, SolidWorks, NX, Mastercam).
• Knowledge of APQP, PPAP, FMEA, SPC, and MSA.
• Strong project management and cross-functional coordination skills.
• Excellent problem-solving and analytical abilities.
• Effective communication and customer handling skills