Division

Department

Engineering

Level / Grade

L3

Functional Area

Welding Technology

1

Job Title

Welding Process planning & development – Automotive Welded assemblies

2

Reporting

Functional reporting to: GM (Engg. _ P&F; _ Welding Technology)

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Background i) Educational Qualification

- Desirable: B.E. Mech / M. Tech (Welding Technology) _ Preferred ii) Experience

Minimum: 3

Maximum: 10

iii) Age Limit

Minimum: 25

Maximum: 35

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Job Role & Responsibilities

Role: Planning and Development of Innovative Joining Technologies e.g. Welding, Soldering, Brazing etc. for 2Wh EV components (e.g. Battery, Motor etc) & 2Wh / 3Wh IC components (e.g. Fuel tank, Frame body, silencer & CV (commercial vehicle) weldments

Responsibilities:

New Process Development

- Explore development and productionization of innovative welding technologies
- Adoption of emerging welding technologies (e.g. SM laser with core + ring beams & LDD; EBW, FSW etc.)
- AI adoption (data annotation), analysis, digital twin) – smart manufacturing

Process Planning

- Design simplification & rationalization of new model parts & identifying DFM/A, PQS-CTQ points.
- Process planning for standard process & process parameters optimization.

Flawless Manufacturing & Product quality enhancement

- Resolution of QSR / Field Quality issues and IHR Quality issues at Vendor
- Improve Process reliability for zero defect supplies
- Aesthetics improvement of weldments.

New Product Development

- Selection of Joining process wrt joint design for new products to achieve zero defect, lowest cost & timely delivery
- To establish necessary Poka-Yoke/interlocks for fool proof manufacturing of weldments.
- Design and development of welding fixtures

Cost reduction & Capital Investment avoidance

- To generate VAVEs for welding parts cost reduction
- Right sizing of equipment for investment cost reduction

Green processes

- Adoption of Green processes in welding
- Resource conservation in welding processes.





Competency Requirements

Technical/ Functional:

- Extensive work exposure in EV components required, e.g. Cell terminals welding in EV battery, copper terminals welding in motor, wave soldering & Surface mounted technology (SMT) for making PCBs, and thorough knowledge of innovative welding technologies like Continuous/Pulse/SM Laser Welding, Parallel Electrode Transistor based Series spot/projection welding, ultrasonic wire bonding etc.
- Work exposure and thorough knowledge about dissimilar material joining (e.g. copper to steel, Aluminum to steel etc.), thin sheet with unequal thicknesses joining (e.g. min. 0.2 mm to max. 3 mm)
- Thorough knowledge of following conventional welding processes: -

1. Robotic MIG/MAG welding
2. Resistance spot/seam (circumferential / mash), projection welding
3. Laser Welding (Continuous/Pulse)
4. TIG Welding (filler/non-filler)
5. Gas Brazing / Induction Brazing / MIG Brazing)
6. Soldering (Wave soldering, SMT etc.)

- Expertise in understanding welding simulation software’s (e.g. Simufact, Sysweld etc.)
- Knowledge of welding metallurgy
- Knowledge of Welding fixture concepts
- Knowledge of welding quality inspection techniques - NDT/DT
- Expertise in setting up optimum weld process parameters.
- Capability to analyze & resolve defects reported.
- Thorough knowledge about process/ fixtures tryout & proving procedures.
- Knowledge about automotive industry standards and regulations applicable.

Soft Skill set:

- Excel, Power Point, SAP, Team Centre, NX Unigraphics, Welding Simulation analysis software’s

Behavioral

- Effective communication with team, vendors & management
- Candidate should be able to work in a dynamic and challenging setting to meet deliveries as per schedule.
- Good Interdepartmental co-ordination skills.

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Likely sources

Organization example-

- EV Battery welding manufacturing industries (e.g. Ather, TACO, Ola, BOSCH, Hero Vida, TVS etc.)
- Laser Welding machine manufacturers (e.g. IPG, Trumpf, Amada, Panasonic)

📌 Mgr (Engg - P&F) (India)
🏢 Bajaj Auto
📍 India