Sheet Metal Tool Design Engineer & New Part Development

Responsible for design, development, and validation of sheet metal tooling (press tools, dies, jigs, and fixtures) and execution of new part development activities from concept to production, ensuring quality, cost, and delivery targets are met.

Key Responsibilities

Tool Design & Development

• Design and develop press tools, progressive dies, compound dies, forming tools, and fixtures for sheet metal components.
• Prepare 2D & 3D designs using CAD software (AutoCAD, CATIA, SolidWorks, UG NX, etc.).
• Conduct feasibility study and design reviews considering manufacturability, cost, and quality.
• Coordinate with tool room for manufacturing and tryout of dies/tools.
• Provide engineering solutions for tool modifications, troubleshooting, and continuous improvement.

New Part Development

• Study customer drawings/specifications and prepare DFMEA, process flow, and feasibility reports.
• Develop manufacturing processes for new sheet metal components (blanking, forming, piercing, bending, deep drawing, etc.).
• Coordinate with customers for design approval, PPAP, and APQP documentation.
• Work with production and quality teams during trial runs, validation, and ramp-up.
• Support supplier development for outsourced tool making and new component development.

Quality & Cost Management

• Ensure tools and parts meet dimensional accuracy, quality standards, and performance requirements.
• Optimize tool design for cost reduction, longer tool life, and ease of maintenance.
• Conduct root cause analysis and corrective action for tool-related issues.

Cross-functional Coordination

• Collaborate with customers, suppliers, and internal teams (production, purchase, quality, tool room).
• Support new RFQs with tool cost estimation and feasibility analysis.

Qualifications

• Diploma / B.E. / B.Tech in Mechanical / Production / Tool Engineering.
• 38 years of experience in sheet metal tool design and new part development.

Skills & Competencies

• Strong knowledge of press tool design, sheet metal processes, and GD&T.
• Hands-on experience in CAD software (AutoCAD, CATIA, SolidWorks, UG NX preferred).
• Knowledge of APQP, PPAP, FMEA, and other NPD documentation.
• Problem-solving, analytical, and troubleshooting skills.
• Good communication and project management abilities.

Key Performance Indicators (KPIs)

• On-time completion of tool design and development.
• First Time Right (FTR) success in new tool tryout.
• New part development lead time adherence.
• Cost optimization in tooling and part development.
• Customer satisfaction and approval of new parts.