Senior Component Engineer

Job Title: Component Development Manager – Forging & Machining

Functional Area:

Reporting :

Educational Qualification

Desirable: B.Tech / M.Tech in Mechanical Engineering from IIT / NIT

Experience

Minimum: 5 years - 13 years

Job Role & Responsibilities

Role:

Key Responsibilities:

1. Development & DFM Closure

• Development of gears and shafts through hot & cold forging at vendor locations.
• Study part drawings for feasibility and close DFM comments with R&D and vendors.
• Prepare initial feasibility reports including forging dies, cold forging tool design, tonnage calculations, and forging simulation studies.

2. Vendor Support & Project Execution

• Identify, select, and develop potential vendors (T1 & T2).
• Conduct RFQ feasibility studies, prepare comparative charts, and finalize vendors.
• Provide technical support for tooling, SIR, and process improvements.
• Plan and execute development plans within timelines at vendor locations, resolving constraints, risks, bottlenecks, and quality issues.
• Prepare and review process documents such as PFMEA, PFC, Process Sheets (IPO), SPC, MSA, FTG, FPIR.

3. Techno-Commercial Estimation

• Prepare techno-commercials using zero-based costing.
• Calculate cycle time for CNC, VMC, and other applicable processes.

4. Capacity Enhancement & Process Optimization

• Conduct process improvement analysis and enhance vendor capacity.
• Prepare budgets and techno-commercial synthesis with vendors.

Competency Requirements

Technical / Functional:

• In-depth understanding of forging and gear machining processes.
• Hands-on experience in: hot forging, cold forging, CNC, VMC, broaching, hobbing, shaping, shaving, teeth grinding, teeth honing, bore honing, and heat treatment of gears & shafts.
• Knowledge of automotive standards (DIN / JIS) and gear microgeometry interpretation.
• Proficient in GD&T, tolerance stack-up analysis, AutoCAD, Unigraphics, Kisssoft, ForgeNXT, and MS Office.
• Strong troubleshooting, problem-solving, and process improvement capabilities.
• Experience in technical & cost benchmarking, VA/VE, and alternate sourcing.

Behavioral / Soft Skills:

• Excellent communication, negotiation, and interpersonal skills.
• Strong analytical, team-building, and relationship management capabilities.
• Positive, flexible, and solution-oriented attitude.

Preferred Candidate

• OEM component development and R&D proto shop experience.
• Candidates from leading 2W / 4W manufacturers or similar organizations.