NPD- Sheet Metal

Job role

Sheet Metal tooling and component development

Department

NPD

Function (if applicable)

Manufacturing engineering

Location

Pune

Key Performance Indicators

1. Design and development of press tools

2. Product development (project) completion to agreed / customer due date, Right First Time

List of Critical Tasks (Without which the KPI cannot be achieved) ,

Critical Tasks

Weightage

Knowledge

Skill

Part Feasibility review of parts.

1. conceptualize press tool designs and number of stages after receipt of part drawing.

Identification of failure mode / design errors.

Knowledge and Skill (Mapped to each critical task)

2. Review of GD&T for manufacturing feasibility.

Stagewise process design for stamping process.

Understanding of stagewise process design to optimize number of stages and yield improvement.

Use of process understanding to develop parts of expected quality with min cost & min time to develop the part

1. Cutting operations (blanking, sharing, piercing, trimming).

2. Bending (V bending, edge bending).

3. Deep draw

4. forming processes

Prepare Quality plan of the product to be developed.

1. P FMEA

Use of product and process knowledge to build the P FMEA for Tool & Process.

2. Rapid detection / poka-yoke

Approve the Tool design

3. Types of Press Tools

Use of knowledge to make tooling to produce expected quality product with inbuilt poka-yoke, rapid detection systems

(Back up calculations to meet the product dimensions, Tool construction)

4. Design verification of Press Tools

5. Material Selection as per Operation

6. Heat Treatment

7. Tonnage Calculation - Press Selection

8. Spring back calculation and compensation, blank size calculation

Manufacturing of tool/Fixture / Gauges concept.

Manufacturing of tools, elements machining, heat treatment.

Use of process understanding to make product defect free.

Tool assembly.

Tool inspection and approval.

Track the projects for progress of tooling development.

1. Project Management

To ensure project completion happens within customer due date time.

2. Review the tool /Part progress with supplier (Active task management)

3. Tool inspection review along with suppliers.

4. Tool tryout and trouble shooting.

Conduct stage wise PPAP at component manufacturer

IATF 1649 System knowledge

Stage wise PPAP, Implementation of IATF 16949,

Quality Documents - APQP , PPAP , FMEA, SPC , MSA

Review process costing & give inputs to costing team.

Process understanding

Identify patterns (pattern recognition), Maintain a database.

1. Draw , forming processes

To facilitate cost negotiations with suppliers.

2. Machining processes

3. Coating processes

4. Fabrication

Continual improvements in processes to improve upon Quality , cost , delivery

Problem solving techniques

Understand

1. 7 step problem solving-Data Collection

2. 8 D-Observations

3. 6 Sigma-Patterns through observations.

Experience

10-15 years’ experience in similar industry & function

(Age 30- 35 years)

Qualification

BE Mechanical / DME + Tooling

Professional Courses

Tool design & manufacturing