Reports to: Engineering and Development Head Direct Subordinates: Assistant Manager / Deputy Manager /Asst Engineer/ Engineer /Sr Engineer – E&D PRINCIPAL DUTIES AND RESPONSIBILITIES: • Drawing/3D data study for stamping parts and BIW assy. For four wheelers (Spot welding and Mig welding) 1. Studying and understanding drawings and 3D data received from customer. 2. Identifying critical to quality parameters/ dimensions. 3. Preparing process for manufacturing. 4. Having knowledge of GD&T. • Proto parts production. 1. Designing process, equipment’s for proto parts production. 2. Testing of parts followed by submission to customer. • Requirement analysis for new projects and capacity planning for existing models for BIW Assy. 1. Study and calculate various requirements in terms of SPM’s, robots, weld jigs, Spot welding and Mig welding cells, checking fixtures, etc for new projects. 2. Capacity planning of projection welding /Spot welding machines/ SPMs in case of new model addition. 3. Capacity planning/ Duplicate weld line requirement in case of volume enhancement. 4. Ordering of equipment’s/machines/robots as per specifications. • Design and development of weld jigs/ checking fixtures / SPM’s for BIW Assy. 1. Co-ordinate with line integrator/designer for design of weld jigs/ checking fixtures as per ease of manufacturing process and customer requirements. 2. Design approval of weld jigs/ checking fixtures of BIW assy. (Spot welding and Mig welding) 3. CMM inspection/ validation of weld jigs and checking fixtures. 4. Weld cells/ weld line design, approval and installation. 5. Robotic simulation study and feedbacks to line integrators. • Conducting spec meeting with Customers 1. Preparing various annexures for spec meetings. 2. Co-ordinating with press team/ design team for simulation and die layout of stamping parts. 3. Preparing checking fixture concepts, weld jig concepts and past defects problems and analysis data. 4. Co-ordinating with customer for approvals/ closures of spec meeting. 5. Stamping parts checking fixtures and Assy. Checking fixtures design concept approval with customer. • ECN management 1. Raising ECR’s for any problem observed during simulations, design study and trials. 2. Checking feasibility of ECN received from customer. 3. Floating ECN data to suppliers, tool makers, Line integrators and follow ups for the same. 4. Preparing ECN implementation time lines, its cost impact and discussing the same with customer. 5. CAD features verification of ECN implemented parts through scanning and CAD data. • Conducting weld trials and inspection of child parts as well as assemblies. 1. Line installation activities. 2. Preparing inspection formats for child parts as well as assemblies. 3. Inspection of parts on checking fixtures. 4. Guiding tool makers for child part development as per feedbacks of trials. 5. Joint inspection of parts with customer. 6. Preparing jig hankie for improvements and closure of the same. • Commissioning of weld lines. • Customer related activities. 1. Conducting spec meetings. 2. Joint inspection with customer. 3. Understanding customer concerns during development and closure of the same accordingly. 4. Horizontal deployment of all customer related defects in new projects. 5. PPAP documentation readiness and approval of the same from customer. 6. Conducting FMEA meetings with customer as well as internal CFT. 7. Conducting customer audits ( VSA, IATF, Etc ) • Raw material testing during development stage. 1. Getting physical and chemical composition testing done for raw materials/ BOP’s etc. 2. Preparing samples for testing at customer’s lab. 3. Co-ordinating with customer for specific requirements during testing stage. • Internal plant activities. 1. GEMBA for any in-house or customer related defects/ feedback. 2. Conducting APQP meeting with internal CFT for new development projects. 3. KAIZEN activities for continuous improvement and waste reduction. Show more Show less