: Lead / Senior Engineer New Product Development (Casting, Forging & Machining)

- Company Name: Matel Motion
- Location: Khed Shivapur / Bavdhan (Pune)
- Experience: 5–8 Years
- Education: B.E. / B.Tech / Diploma in Mechanical, Production, or Automobile Engineering
- Industry / Domain: Automotive / Industrial Manufacturing / Drivetrain & Powertrain

Position Summary: We are looking for an experienced and driven New Product Development (NPD) Engineer to spearhead the end-to-end development and industrialisation of critical metallic components across Aluminium Casting (HPDC/GDC/LPDC) and Forging & CNC Machining. The candidate will manage component life cycles from drawing review and supplier feasibility through tooling, prototype trials, quality validation, PPAP approval, and handover to serial production (SOP).

Key Roles & Responsibilities:

1. Manufacturing Process, Tooling & Industrialisation

- Casting: Lead development of aluminium cast components using HPDC, GDC, or LPDC processes. Review die designs, runner/gating systems, thermal balance, cooling layouts, and shot parameters to drive cycle-time and yield optimisation.
- Forging & Machining: Oversee forged component development (hot/warm/cold forging), die designs, grain-flow orientation, trimming, and heat treatment. Coordinate CNC/VMC machining setups, fixture design, tool/insert selection, and datum alignment.
- Tooling Trials & Validation: Supervise T0/T1 tool trials, sample generation, dimensional layouts, and prototype evaluations, resolving tooling and process bottlenecks before mass production.

2. Quality, Engineering Controls & Defect Prevention

- Review and interpret 2D engineering drawings, 3D CAD models, material grades, GD&T;, surface finishes, and critical machining datums.
- Proactively identify and eliminate manufacturing defects:




- Casting: Porosity, shrinkage, cold shuts, cracks, inclusion, and pressure leakage.
- Forging & Machining: Underfill, laps, scale pits, chatter, dimensional drift, and tool wear.
- Coordinate mechanical/metallurgical validation, leak testing, NDT (MPI/UT), microstructure evaluation, and CMM dimensional inspection.

3. Costing & RFQ Management

- Prepare hands-on should-costing and bottom-up cost models for casting, forging, secondary operations, and precision machining.
- Perform RFQ reviews, technical evaluations, supplier quotation comparisons, and tooling capex negotiations to support strategic sourcing.

4. Project Management & APQP / PPAP Deliverables

- Drive automotive core tools and APQP milestones: Process Flow Diagrams (PFD), PFMEA, Control Plans, Measurement System Analysis (MSA), and Capability Studies (C_p / C_{pk}).
- Compile and lead Level 3/4 PPAP submissions, managing customer and internal approvals up to standard serial handover (SOP).
- Coordinate cross-functionally with Design, Quality, Sourcing/Purchase, and Production teams to ensure on-time milestone delivery and budget adherence.

Required Skills & Qualifications:

- Technical Expertise: In-depth knowledge of aluminium casting metallurgy (HPDC/GDC/LPDC), steel forging processes, heat treatment, and precision CNC/VMC machining.
- Core Tools & Standards: Hands-on proficiency in APQP, PPAP, PFMEA, Control Plans, SPC, MSA, and IATF 16949 standards.
- Drawing & CAD: Strong command of GD&T;, tolerance stack-up analysis, and familiarity with CAD platforms (Creo / CATIA / SolidWorks / NX).
- Cost & Vendor Management: Robust acumen in component should-costing, raw material indexation, and supplier quality audits.
- Soft Skills: Excellent cross-functional coordination, problem-solving (8D, 5-Why), and vendor development skills.

📌 NPD Engineer Castings, Forgings, Machining (Pune)
🏢 InterviewPanel
📍 Pune