Division

BAL - Akurdi

Department

Materials

Level / Grade

L3 / EX

Functional Area

Component Development – Forging & Machining

1

Job Title

Component Development Manager

2

Reporting

Functional reporting to: Divisional Head (CD F&M;)

3

Background i) Educational Qualification

Desirable: B.Tech/ M.Tech (Mechanical) - IIT / NIT ii) Experience

Minimum: 7 years

Maximum: 12 years iii) Age Limit

Minimum: 27 years

Maximum: 34 years

4

Job Role & Responsibilities

Role: Component Development – Gears and Shafts

Responsibilities:

Development of Gears and Shafts by hot & cold forging at Vendor end

Drawing Feasibility & DFM Closure -

- Part drawing feasibility Study and closure of DFM comments with R&D; & Vendors
- Preparation of initial feasibility which includes Forging dies /Cold forging tool design, Tonnage calculations, Forging Simulation study.

Vendor Support & Sample Development / Project Execution -

- Selection and development of potential vendors (T1 & T2) - RFQ feasibility Study, preparation of comparative chart and selection of best vendor
- Selection & Procurement – MFGT (Machines, Fixtures, Gauges & Tools) Techno commercial discussion
- Provide strong technical support to vendors, SIR and process improvement
- Plan, co-ordinate and execute development plans within timelines at Vendor end by identifying & resolving the constraints, risks & bottle necks and quality issues.
- Preparation & review of process documents such as PFMEA, PFC, Process Sheets (IPO), SPC, MSA, FTG, FPIR.

Techno-Commercial Estimation (Zero-Based Costing) -





- Preparation of Techno-Commercials based on Zero-based costing, Calculation of Cycle time for CNC, VMC and other applicable processes

Capacity Enhancement & Process Optimization -

Capacity process improvement analysis and enhancement, budgeting and techno-commercial synthesis with Vendors.

5

Competency Requirements

Technical/ Functional -

In-depth understanding of forging and Gear machining processes -

Hands on experience with processes – Hot forging, Cold forging, CNC, VMC, Broaching, Hobing, Shaping, Shaving, Teeth grinding, teeth honing, bore honing and good knowhow of Heat Treatment for Gears & shafts

Aware of Automotive standards applicable for Gears and Shafts - Din / JIS - Gear microgeometry interpretation & problem solving - Conversant with latest trends in Gear manufacturing

Well versed with GD&T; and tolerance stack up analysis, AutoCad, Unigraphics, Kisssoft, MS Office, ForgeNXT

Good troubleshooting and problem-solving abilities with proven ability in driving process improvement and cost savings (Alternate sourcing & VA/VE).

Technical & cost benchmarking with competitors in global industry

Behavioral -

- Excellent communication, negotiation & interpersonal skills with solid analytical, team building capabilities.
- Strong relationship building & interpersonal skills, possessing a positive & flexibility-oriented attitude.

6

Likely sources

Organization –

Preference for OEM’s Component development and R&D; proto shop group ---

Hero MotoCorp, Maruti, Any 2W/4W Manufacturer ++

📌 MGR (MATLS-F&M CD Engine) (India)
🏢 Bajaj Auto
📍 India