Company Description Sunny Engineers, founded in 2000 as an extension of Nirmiti Stampings Pvt. Ltd. (established in 1995), brings over three decades of expertise in sheet metal stampings. The company specializes in manufacturing precision press metal and non-metal components and assemblies.

With a strong focus on quality and reliability, Sunny Engineers serves diverse industrial sectors. Its products are supplied across India, South-East Asia, Europe, South America, and North America, offering team members exposure to global manufacturing standards.

JOB DESCRIPTIONNew Part Development & Process Engineer – Sheet Metal Stamping

Department: Engineering / New Product Development (NPD)

Designation: New Part Development & Process Engineer

Industry: Automotive / Auto Components / Sheet Metal Manufacturing

Reporting To: Management

Experience: 3–7 years (customizable)

Qualification: Diploma / B.E. / B.Tech. in Mechanical, Production, or Manufacturing Engineering

1. Job Purpose

To manage end-to-end development of new sheet metal stamping parts, from customer drawing review and feasibility analysis to tooling development, process planning, sample submission, validation, and successful handover to mass production. Ensure that all new parts meet customer requirements for quality, cost, delivery, productivity, and manufacturability.
1. Key Responsibilities

A. New Part Development

- Review customer drawings, 2D/3D models, technical specifications, and applicable standards.
- Conduct manufacturability reviews and feasibility studies for new sheet metal stamping components.
- Coordinate with customers regarding drawing clarifications, technical requirements, and engineering changes.
- Prepare development plans, timelines, milestones, and project tracking reports.
- Ensure timely completion of current part development as per customer schedules.

B. Process Planning and Development

- Develop the complete manufacturing process flow for sheet metal stamping parts.
- Determine blank size, strip layout, material utilization, operation sequence, and process parameters.
- Select suitable press capacity, tonnage, stroke, bed size, shut height, and feeding arrangements.
- Define stamping operations such as blanking, piercing, bending, forming, drawing, trimming, and restriking.
- Optimize process parameters to achieve dimensional accuracy, stable production, and minimum rejection.
- Identify opportunities to reduce cycle time, scrap generation, and manufacturing cost.

C. Tool and Die Development

- Coordinate with tool design, tool room, and external tool vendors for new stamping dies.
- Review die concepts, tool layouts, and designs for feasibility and manufacturability.
- Monitor die manufacturing, tryout, correction, and commissioning activities.




- Conduct die trials and troubleshoot issues related to burrs, wrinkles, cracks, springback, distortion, and dimensional variation.
- Ensure proper implementation of die protection, poka-yoke, and mistake-proofing systems wherever required.

D. Material and Cost Estimation

- Review raw material specifications, grade, thickness, coating, and mechanical properties.
- Calculate blank weight, net component weight, scrap percentage, and material utilization.
- Prepare preliminary process cost estimates, tooling cost inputs, and cycle-time estimates.
- Identify cost-reduction opportunities through process optimization, nesting improvement, and scrap reduction.
- Support cost negotiations and technical discussions with customers and suppliers, as required.

E. Quality Planning and Validation

- Prepare and coordinate APQP activities, PFMEA, Process Flow Diagram, Control Plan, and related quality documents.
- Support preparation of inspection standards, dimensional reports, and process validation records.
- Coordinate initial sample inspection and submission through ISIR/PPAP, as applicable.
- Conduct dimensional verification and functional validation of new components.
- Ensure compliance with customer-specific requirements and applicable quality standards, including IATF 16949 where relevant.
- Drive root-cause analysis and corrective actions for development-stage quality issues using 8D, 5 Why, Fishbone, and other problem-solving tools.

F. Trial, Production Readiness, and Handover

- Plan and execute die trials, sample production, and process capability studies.
- Coordinate with Production, Quality, Maintenance, Tool Room, Purchase, and Suppliers to resolve development issues.
- Establish standard operating parameters, work instructions, inspection methods, and process settings.
- Ensure readiness of tooling, material, gauges, fixtures, manpower, and production equipment before launch.
- Complete successful handover of approved parts and processes to mass production.
- Monitor initial production performance and implement improvements to stabilize the process.

G. Documentation and Reporting

- Maintain part development trackers, trial reports, feasibility records, and engineering change documentation.
- Prepare and maintain process sheets, operation standards, tooling records, and lessons learned.
- Track development KPIs such as on-time development, first-time-right samples, rejection rate, material utilization,



and tooling readiness.
- Ensure proper revision control and traceability of drawings, specifications, and technical documents.

1. Technical Skills and Competencies

- Strong knowledge of sheet metal stamping processes and press shop operations.
- Understanding of progressive dies, compound dies, and stage/transfer dies.
- Knowledge of die design concepts, strip layout, blank development, and material utilization.
- Ability to interpret engineering drawings, GD&T;, tolerances, and 2D/3D models.
- Understanding of sheet metal grades, material properties, thickness variation, springback, and formability.
- Experience in press tonnage calculation, cycle-time estimation, and process feasibility.
- Knowledge of APQP, PPAP, PFMEA, Control Plans, MSA, SPC, and problem-solving methodologies.
- Proficiency in MS Excel, PowerPoint, and technical reporting.
- Working knowledge of CAD tools such as AutoCAD, SolidWorks, CATIA, or UG/NX; stamping simulation knowledge is an advantage.
- Understanding of 5S, Kaizen, Poka-Yoke, and continuous improvement practices.

1. Key Performance Indicators (KPIs)

- On-time completion of new part development milestones.
- First-time-right sample approval rate.
- Number of development trials required per part.
- Tooling development and commissioning lead time.
- New part rejection and rework rates during trials and initial production.
- Material utilization percentage and scrap reduction.
- Achievement of target cycle time and estimated manufacturing cost.
- Timely completion of APQP/PPAP documentation.
- Successful transfer of recent parts to mass production without major quality issues.

1. Experience and Eligibility

- 3–7 years of relevant experience in sheet metal stamping, NPD, process engineering, or tooling development.
- Practical experience in die trials, process troubleshooting, and new component development.
- Experience in the automotive or auto-component manufacturing industry is preferred.
- Ability to coordinate effectively with customers, tool vendors, and cross-functional internal teams.
- Strong analytical, communication, planning, and problem-solving skills.

1. Key Interfaces

- Customer Engineering and Quality Teams
- Tool Design and Tool Room
- Production and Press Shop
- Quality Assurance and Quality Control
- Purchase and Supplier Development
- Maintenance and Manufacturing Engineering
- Project Management and Sales/Commercial Teams

1. Expected Outcome

Successfully develop sheet metal stamping parts that meet customer specifications, achieve target cost and quality, are delivered within the agreed development timeline, and can be manufactured consistently and efficiently in mass production. Pay: ₹45,000.00 - ₹60,000.00 per month

Work Location: In person

📌 NPD and Process engineer (Kurali)
🏢 SUNNY ENGINEERS
📍 Kurali