Head of Product Design

Head of Department - Product Design

Manesar

Research & Development / Product Engineering

Reporting: General Manager

Reports: Managers/AM Product Design, Design Engineers, as per organization chart

Job Summary:

Head of Department - Product Design will lead the Interior & Exterior Trims product design department. This is a senior leadership position responsible for the entire design-to-production lifecycle, from concept ideation and aesthetic design to engineering for manufacturability (DFM) and launch of all interior and exterior trim components for our automotive products. Strategic thinking with a deep understanding of design principles, materials science, manufacturing processes, and market trends are prerequisites. You will be responsible for building, mentoring, and inspiring a team of talented designers to deliver innovative, cost-effective, manufacturable, aesthetically pleasing, and functionally superior products that and meet the highest quality standards and set new industry standards.

Key Responsibilities (KRAs):

• End-to-End Product Development:

• Oversee the entire design process for plastic parts:

  conceptual sketches

  ,

  3D CAD modelling

  (Surface & Solid) that align with

  customer design language

  , prototyping, validation, and production launch.
• Ensure all designs meet critical requirements: aesthetics, function, cost, weight, timing, and quality.
• 3D CAD Mastery: Ensure expert-level 3D data creation. This includes:

• Class-A Surface Development

  : Supervising the creation of mathematically perfect, curvature-continuous surfaces for visible components.

• Solid & Functional Modelling

  : Overseeing the design of internal structures, ribs, snap-fits, living hinges, and mounting features.

• Software

  : Ultimate authority on best practices for

  Siemens NX

  .

• Design for Excellence

  (DFX): Champion and enforce rigorous application of principles specific to injection moulding, over-moulding, and other relevant processes.

• Design for Manufacturing

  (DFM): Ensuring all designs are optimized for the injection moulding process (e.g., uniform wall thickness, adequate draft angles, appropriate radiations to avoid sink marks).

• Design for Assembly

  (DFA): Designing for ease and efficiency of assembly with other components (e.g., fool-proofing, clear locating features).

• Design for Cost

  (DFC): Driving cost-out initiatives through part consolidation, material selection, and design simplification.

• Design for Quality & Durability

  : Implementing robust designs that meet performance criteria (e.g., fit & finish, gloss levels, scratch resistance, chemical resistance, thermal cycling).

• Tolerancing & Documentation:

  Ensure all 2D drawings are meticulously detailed with full

  Geometric Dimensioning and Tolerancing (GD&T)

  and comprehensive tolerance stack-up analyses are performed.

• Strategic Leadership & Team Management:

• Lead, mentor, and develop a multidisciplinary team of product Designers, CAD Engineers, and Project Designers.
• Define the department's technical vision, strategy, and roadmap aligned with company goals.
• Manage resource allocation, workload planning, and departmental budgets.
• Drive a culture of innovation, continuous improvement, and excellence in execution.
• Assign and monitor project tasks and deadlines.
• Foster a collaborative and productive work environment.
• Effective team management involves:

• Talent Development:

  Identifying training needs and providing opportunities for team members to enhance their skills.

• Performance Management:

  Setting clear performance expectations, providing regular feedback, and conducting performance reviews.

• Conflict Resolution:

  Addressing and resolving conflicts within the team in a timely and professional manner.

• Resource Allocation:

  Effectively allocating resources (personnel, equipment, software) to ensure project success.

• Promoting innovation:

  Encouraging the team to bring forward new ideas, and better design solutions.

• Skills Gap Analysis:

  Identifying the skills needed for current and future projects and developing training programs to address any gaps.

• Performance Coaching:

  Providing regular feedback, mentoring, and coaching to team members to improve their performance.

• Succession Planning:

  Identifying and developing high-potential employees to take on leadership roles in the future.

• Project Management:

• Develop and manage project timelines and budgets.
• Track project progress and identify potential delays.
• Ensure projects are completed on time and within budget.
• Successful project management requires:

• Risk Management:

  Identifying and mitigating potential risks that could impact project timelines or budgets.

• Change Management:

  Effectively managing changes to project scope or requirements.

• Communication:

  Maintaining clear and consistent communication with stakeholders throughout the project lifecycle.

• Scheduling:

  creating and maintaining project schedules.

• Documentation:

  Ensuring that all project documentation is accurate and up-to-date.

• Technical Expertise & Quality Assurance:

• Implement and maintain quality control procedures.
• Provide expert guidance on material selection (e.g., ABS, PC, PP, TPEs, composites) and finishing processes.
• Oversee the resolution of complex technical challenges related to tooling, moulding, part assembly, and performance.
• Establish and enforce stringent quality standards and design validation protocols.
• Lead root cause analysis and implement corrective actions for design-related issues.
• Staying current with industry trends and technologies is crucial:
• Advanced Moulding Technologies: Understanding and implementing advanced product design methodologies.
• Simulation Software: Utilizing advanced simulation software to optimize product designs and predict performance.
• Material Science: Keeping up to date with new materials that can be used for moulding.
• Standardization of processes: ensuring that all processes are standardized to increase efficiency and reduce errors.

Continuous Improvement:

o  Develop and standardize design processes, best practices, and documentation.

o  Drive the adoption of new technologies and software.

o  Stay abreast of industry trends in materials, manufacturing technologies, and design aesthetics.

o  Promote and implement lean manufacturing principles and continuous improvement methodologies to enhance plant performance.

o  Identify opportunities for process optimization, waste reduction, and efficiency increase.

Cross-Functional Collaboration & Client Management:

• Serve as the primary design authority, liaising closely with Tooling, Manufacturing, Quality, and Procurement departments.
• Partner with Project Management to ensure flawless execution and on-time delivery of all design milestones.
• Interface directly with key clients (OEMs) to understand their design language, technical specifications, and requirements. Present design proposals and lead technical reviews.

Reporting and Documentation:

o  Prepare regular reports on department performance for senior management.

o  Maintain accurate records of design output, production data, inventory, safety incidents, and compliance documentation.

Regulatory & Safety Compliance:

o  Ensure that the department operates in compliance with all relevant laws, regulations, and environmental standards.

o  Maintain necessary permits and licenses for department operations.

o  Follow & ensure adherence to company policies / directives.

o  Ensure the safety of all personnel within the department by enforcing safety regulations and procedures.

o  Conduct regular safety inspections and implement corrective actions as necessary.

o  Provide safety training to department staff.

o  Energy conservation.

Maintenance and Asset Management:

o  Oversee maintenance programs to ensure machinery and equipment are in optimal working condition.

o  Schedule and perform preventive and corrective maintenance activities for tools and equipment to minimize downtime and ensure optimal performance.

o  Manage capital expenditures for equipment upgrades, replacements, and maintenance projects.

o  Oversee the maintenance and repair of all department equipment, including computers, software, measuring/ testing instruments.

o  Troubleshoot and resolve equipment malfunctions as needed in coordination with maintenance, IT or other required departments.