1) Job Purpose: Write the purpose for which the job exists (in 2-3 lines)

- The SME – New Product Development & Design Services leads all recent product development (NPD) initiatives for the IGT (Inner Grooved Tube) manufacturing plant at Waghodia, Vadodara. The role is responsible for identifying, conceptualising, developing, and commercially qualifying new IGT variants and copper tube grades — including new OD / wall thickness combinations, groove geometries, alloy grades, and coil configurations — in response to evolving customer requirements, energy efficiency mandates, and competitive market dynamics. The incumbent works at the intersection of process engineering, metallurgy, product design, and customer technical service — translating customer needs and technology trends into manufacturable, quality-compliant, commercially viable new products. As India's first IGT plant, this role plays a critical part in establishing Hindalco's product leadership in the domestic and export IGT market.

2) Dimensions: Mention quantitative or qualitative parameters that are relevant for the job and provide a better understanding of the scope and scale of the job.

Product Scope

Inner Grooved Tubes (IGT) – Level Wound Coils (LWC); Plain Copper Tubes – LWC, Straight Tubes, Pancake Coils; New alloy grades and geometric variants as per customer / market requirements

Plant Capacity

25,000 TPA (20,000 TPA IGT + 5,000 TPA Plain Tube) – First IGT plant in India; PLI Scheme beneficiary

NPD Scope

New OD / wall thickness / groove geometry combinations; new alloy grades (copper and copper alloys); new coil / packaging configurations; process parameter development for new products

Customer Qualification Scope

OEM AC manufacturers (domestic & export); refrigeration & HVAC OEMs; heat exchanger manufacturers; distributor qualifications for new grades

Standards & Specifications

ASTM B75, B88, B280, B743; EN 12735; JIS H3300; IS 1545; customer-specific proprietary specifications; energy efficiency rating standards (BEE, AHRI, etc.)

Key Interfaces

Production / PBU team; COE Process Care & Quality; R&D; / ABSTC / HIC; Commercial / Sales team; Customers (OEM technical teams); Equipment OEMs (IGT machine suppliers)

Reporting

Reports directly to COE Head – Process Care & Quality; collaborates closely with SME – Process & Quality and SME – Customer Handling & Technical Services

Function Workforce

MG – 4, LMS – 14, Contract Workmen – 3 | Total COE PCQ team = 21

Other Quantitative and Important Parameters for the job:

Budgets / Volumes / No. of Products / Geography / Markets / Customers or any other parameter

Hindalco's IGT plant is India's first Inner Grooved Tube manufacturing facility and a PLI scheme beneficiary. IGTs are used in energy-efficient air conditioners and refrigeration systems; the global trend toward smaller OD tubes (7mm, 5mm, and below) with complex groove geometries is driven by regulatory energy efficiency standards (BEE star ratings, AHRI standards). The NPD role is responsible for keeping the plant's product portfolio ahead of these evolving requirements.

Target new product categories include: ultra-thin wall IGTs (wall thickness ≤ 0.19mm), smaller OD IGTs (5mm and below), enhanced groove geometry variants (multi-start, high-helix, herringbone), copper-alloy IGTs for specialised applications, and new plain tube grades for plumbing, medical gas, and industrial applications.

New product qualification timelines with OEM customers can range from a few weeks to more than 3 months, involving multiple sample submission rounds, dimensional / mechanical / performance testing, and field trials at the customer's assembly line. The SME must manage multiple concurrent NPD projects across different customers and product types.

3) Job Context & Major Challenges: Write the specific aspects of the job that provide a challenge (internal and external) to the jobholder in the context of the Business/Unit/Function/Department/Section

First-Mover Complexity in India: As India's first and only IGT manufacturer, there are no domestic precedents or industry benchmarks to draw from for new product development. The SME must rely on deep technical knowledge of copper metallurgy, IGT forming processes, and international standards — combined with direct interaction with global IGT manufacturers and equipment OEMs — to develop and validate new products in an environment where the learning curve is entirely self-built.

Rapidly Evolving Customer Specifications: IGT customers (AC OEMs) continuously revise product specifications in response to tightening BEE energy efficiency norms, AHRI rating requirements, and their own heat exchanger design improvements. New groove geometry, OD, and wall thickness combinations are requested with increasing frequency and shorter lead times. The SME must anticipate these changes proactively rather than react to them.

Ultra-Thin Wall Manufacturing Complexity: Developing IGTs with wall thicknesses of 0.19mm and below pushes the limits of the plant's current manufacturing capability. Achieving consistent dimensional tolerances, groove geometry accuracy, surface finish, and mechanical properties at these gauges requires precise process parameter development, tooling design optimisation, and annealing cycle validation — all of which must be done without disrupting the regular production schedule.

Customer Approval Process: Every new product or product variant supplied to a new customer requires a rigorous qualification process — sample submission, dimensional inspection, mechanical testing, heat transfer performance testing (in some cases), and field trials at the customer's assembly line. This process can take weeks to months and may involve multiple iteration cycles. Managing multiple concurrent customer approvals for different product variants demands strong project management and technical documentation capabilities.

Process–Product Interface: New product development at the IGT plant is deeply intertwined with the manufacturing process — die design, rolling parameters, annealing temperature/time profiles, drawing speed, and coiling tension all directly affect the final tube dimensions, groove geometry, mechanical properties, and grain structure. The SME must bridge the gap between product design requirements and process engineering capability, working closely with the production and process care teams to translate new product designs into stable, repeatable manufacturing processes.

Intellectual Property & Design Confidentiality: Groove geometry designs and proprietary copper alloy formulations are areas of competitive differentiation. The SME must manage new product design information with appropriate confidentiality protocols, especially when sharing sample data with customers or collaborating with external R&D; partners — balancing technical transparency with IP protection.

Building NPD from Scratch: The Waghodia IGT plant is in its early operational phase.



The SME must simultaneously build the NPD framework — tollgate process, test protocols, documentation standards, customer interaction processes — while also executing active new product development projects. This dual responsibility of system-building and project delivery requires strong initiative, self-direction, and the ability to work in an ambiguous, start-up-like environment.

4) Key Result Areas: Write the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4-7 key result areas)

Supporting Actions

Key Result Areas

Supporting Actions

New Product Development – IGT & Copper Tube Variants

- Lead the end-to-end NPD process for new IGT and copper tube products: idea generation, feasibility assessment, process parameter development, prototype manufacturing, testing, and commercial qualification — following the plant's NPD tollgate framework.
- Develop new IGT variants based on customer and market requirements: new OD and wall thickness combinations (5mm, 7mm and emerging smaller sizes), groove geometry variants (groove count, helix angle, groove depth, tip width), recent fin-pitch compatibility profiles, and new coil configurations (LWC spool sizes, inner diameter, traverse pitch).
- Develop plain copper tube grades for new applications: plumbing (EN 1057 / ASTM B88), medical gas (HTM 02-01 / ISO 15001), refrigeration (ASTM B280), industrial / heat exchanger tubes — including current wall thickness and temper (O, H55, H58, H80) variants.
- Identify and develop new copper alloy grades for specialised IGT or tube applications where pure copper (C12200) does not meet the customer's thermal, mechanical, or corrosion resistance requirements.
- Coordinate prototype manufacturing trials with the PBU production team; define trial parameters, monitor trial runs, collect samples, and analyse results against target product specifications.
- Prepare and maintain NPD project charter, development plan, test reports, sample dispatch records, and qualification status tracker for all active NPD projects.
- Evaluate and close NPD projects with clear technical and commercial go / no-go decisions; document learnings for future reference and update the plant's product design database.

Process Parameter Development & Optimisation for New Products

- Develop and optimise manufacturing process parameters for each new product: drawing die design (die angle, bearing length, approach angle), annealing cycle (temperature, time, atmosphere, cooling rate), coiling tension, and finishing parameters — to achieve target dimensions, grain size, mechanical properties, and surface finish.
- Conduct Design of Experiments (DOE) for critical process variables affecting new product quality; analyse results using statistical tools (Minitab / SPC software) to identify optimal process windows and establish control limits.
- Establish process control plans, inspection standards, and Standard Operating Procedures (SOPs) for all new products before commercial release; ensure these are reviewed and approved by the COE Head – Process Care & Quality.
- Define critical-to-quality (CTQ) characteristics for each new product and establish the measurement plan, acceptance criteria, and SPC parameters for in-process and final inspection.
- Conduct process capability studies (Cp / Cpk) for recent products; ensure all CTQ characteristics achieve Cpk ≥ 1.33 before commercial qualification; identify and resolve capability gaps through process parameter refinement.
- Collaborate with the SME – Process & Quality and DMT Quality teams to validate measurement systems (Gauge R&R;) for new product inspection dimensions; ensure measurement accuracy is adequate for the tight tolerances of ultra-thin IGTs.
- Document all new product process parameters in the plant's process parameter database; implement change control for any post-qualification parameter modifications.

Customer Sample Development & Qualification Management

- Manage the complete customer qualification process for recent products: from initial customer enquiry and sample specification review, through prototype development, sample submission, testing coordination, iteration cycles, and final customer approval.
- Prepare technically accurate sample dispatch packages for customer qualification: sample tubes with full dimensional reports (OD, wall thickness, groove geometry measured by profilometer / microscope), mechanical test certificates (tensile, hardness, elongation), metallurgical reports (grain size, microstructure), and chemical composition certificates.
- Coordinate heat transfer performance testing for IGT samples where customer qualification requires performance data (Nusselt number, heat transfer coefficient, pressure drop); liaise with ABSTC, HIC, or accredited testing laboratories for test execution and report preparation.
- Track and manage all customer sample submissions and qualification status: maintain a qualification matrix showing submission date, customer test status, iteration round, and expected decision date for each product-customer combination.
- Respond to customer technical queries on new products: dimensional deviations, mechanical property clarifications, alloy composition questions, and test methodology discussions; prepare written technical responses in a clear and professional manner.
- Facilitate customer plant visits and technical meetings for new product reviews; coordinate with the COE Head – Process Care & Quality and commercial team for customer-facing technical engagements.
- Upon customer approval, support the handover of the new product to the SME – Process & Quality for regular production; provide the complete process and quality documentation package for production readiness.

Product Design & Engineering Standards

- Maintain and continuously update the plant's product design catalogue: product drawings, dimensional specifications, groove geometry parameters, mechanical property requirements, and permissible tolerance ranges for all IGT and copper tube products.
- Ensure all product designs are compliant with applicable international and customer-specific standards: ASTM B75 / B88 / B280 / B743, EN 12735, JIS H3300, IS 1545, and any customer proprietary specifications.
- Review and interpret new or revised industry standards (ASTM, EN, BIS updates); assess the impact on existing products and initiate design revisions or re-qualifications as required.
- Develop and maintain product data sheets (PDS)



for all IGT and copper tube products in the Hindalco portfolio; ensure PDS are accurate, current, and approved before distribution to customers or the commercial team.
- Support value engineering initiatives: identify product design changes that reduce material consumption (yield improvement), simplify manufacturing (process cost reduction), or improve product performance (heat transfer, strength) without compromising customer specifications.
- Manage product design change control: ensure all design changes (post-qualification) are assessed for impact on existing customers, go through a structured change approval process, and are communicated to affected customers before implementation.
- Maintain intellectual property awareness for proprietary groove geometry designs and alloy formulations; work with the legal / IP team to identify patentable innovations from the NPD programme.

Technology Watch, Benchmarking & Innovation

- Continuously monitor global trends in IGT technology: groove geometry evolution, new OD / wall thickness trends driven by AC OEM design changes, emerging copper alloy grades, new heat exchanger designs (microchannel, all-aluminium), and alternative refrigerants (R32, R454B, R290) and their impact on tube design requirements.
- Benchmark Hindalco's IGT product portfolio against leading global IGT manufacturers (Jintian, Hailiang, Met Tube, LS Metals, Furukawa) in terms of product range, dimensional capabilities, groove geometry variety, and quality levels; identify portfolio gaps and propose NPD priorities to close them.
- Attend and present at relevant industry conferences, technical symposiums, and exhibitions (ASHRAE, RAJAIR, IHRAR, ACR trade events) to stay current with industry developments and represent Hindalco's technical capabilities.
- Establish and maintain technical collaboration with Hindalco's R&D; centres (ABSTC, HIC) and external academic / research institutions for advanced product development, materials research, and process innovation in copper tube manufacturing.
- Explore and propose applications of new technologies in the NPD process: finite element analysis (FEA) for groove geometry optimisation, computational fluid dynamics (CFD) for heat transfer performance prediction, and simulation tools to reduce physical trial cycles.
- Identify technology upgradation requirements for the plant's IGT manufacturing equipment to extend its product capability range; prepare technology assessment reports for the COE Head – Process Care & Quality and Unit Head.

Customer Centricity & Voice of Customer

- Conduct structured Voice of Customer (VoC) exercises with existing and target IGT customers: identify unmet product needs, future specification requirements, pain points with current suppliers, and emerging application areas where new copper tube products could create value.
- Translate customer VoC inputs into structured NPD project proposals: prepare product development briefs with target specifications, estimated development timelines, resource requirements, and commercial potential — for prioritisation by the COE Head and Unit Head.
- Partner with the SME – Customer Handling & Technical Services to provide technical support on product-related customer complaints that have a design / specification root cause; distinguish between manufacturing quality issues (SME Process & Quality's domain) and product design / application issues (SME NPD's domain).
- Support the commercial / sales team in technical pre-sales activities: prepare product presentations, capability documents, and technical comparison tables for customer meetings; accompany the commercial team on customer visits where deep technical product knowledge is required.
- Train the end user / customer on material specifications, tube selection guidelines, and downstream application best practices (bending, flaring, brazing, expansion) — improving customer satisfaction and reducing field failures attributed to application errors.
- Gather and analyse competitor product intelligence: collect competitor product samples from the market, conduct comparative dimensional and performance testing, and prepare competitive benchmarking reports for internal use.

Collaboration with Production, Process Care & R&D;

- Work in close collaboration with the PBU Head – O&M; and production team to schedule and execute NPD manufacturing trials without disrupting the regular production plan; prepare detailed trial plans with machine allocation, trial duration, material requirement, and inspection protocol.
- Collaborate with the SME – Process & Quality for integration of current products into the plant's QMS: joint development of control plans, inspection instructions, and process FMEAs (PFMEAs) for new products before they enter regular production.
- Partner with the COE Head – Asset Care for any tooling, die, or equipment modification required to manufacture new product variants: die design changes, forming tool fabrication, mandrel / plug modifications, or new annealing fixture requirements.
- Coordinate with ABSTC and HIC for advanced R&D; support: alloy development, tribological studies (die-tube interface for thin-wall IGTs), heat transfer characterisation of new groove geometries, and microstructural research for new temper conditions.
- Participate in cross-functional CI (Continuous Improvement) and Value Creation projects where product design inputs can improve yield, reduce scrap, or improve process stability for existing products.
- Support the preparation of technical publications, white papers, or patent applications arising from the plant's NPD programme, in coordination with Hindalco's R&D; and IP teams.

NPD Project Management & Reporting

- Manage the NPD project portfolio using a structured stage-gate / tollgate process: Gate 0 (Ideation), Gate 1 (Feasibility), Gate 2 (Development), Gate 3 (Validation & Qualification), Gate 4 (Commercial Launch) — ensuring each project progresses through defined milestones with documented deliverables.
- Prepare and maintain a consolidated NPD dashboard: number of projects in each stage, target product specifications, customer qualification status, expected launch dates, and any project delays or risks — for review by the COE Head – Process Care & Quality.
- Track NPD KPIs: number of new products developed per year, number of customer qualifications achieved, time from project initiation to first commercial supply, revenue generated from new products in Year 1 and Year 2 post-launch.
- Prepare monthly NPD progress reports for the COE Head; present NPD project status at the plant's management review meetings.
- Ensure all NPD documentation is complete, controlled, and archived: development trial reports, test data, customer correspondence, qualification certificates, process parameter sheets, and approved drawings — maintained in a retrievable document management system.
- Manage NPD-related CAPEX proposals: identify tooling, equipment, or testing instrument investments required for new product capability; prepare investment justification (capability gap, customer requirement, revenue potential) for approval.

📌 SME NPD & Design Services (India)
🏢 Aditya Birla Group
📍 India