NPD (Forging Process)

Job Description

To lead and Manage / Sr. Manager the development of new forged components from concept to production, ensuring quality, cost, and delivery targets are met. Responsible for coordinating design, process planning, tooling development, and trial validation in line with customer requirements and organizational objectives.

Manager /Sr. Manager NPD (Forging Process)

Function / Department:

Industry: Forging (Preferred)

New Production Development (NPD)

Reports To: Head Engineering

Qualification

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

Salary Budget - 15 18 Lacks CTC /Annum

Experience

• 1416 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 Performance Indicators (KPI's)

Proficiency Level

(General Awareness; Working Knowledge; Functional Expert; Mastery)

New product development lead time (Enquiry to PPAP)

First-time-right trial success rate.

Cost reduction and material yield improvement.

Customer satisfaction and project delivery performance.

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.