Job Description: New Product development & Tool design for Hot forged Machined Parts

Position Requirements: To lead and support tool design and new product development activities for hot forged and precision machined automotive components, from RFQ and feasibility assessment through process planning, forging and machining tooling development, prototype trials, process validation, and successful transition to serial production.

The position requires the ability to manage development activities from initial customer enquiry and drawing review through:

- Technical feasibility and manufacturability assessment.
- Forging process and sequence development.
- Forging die and tooling concept development.
- Machining process planning and tooling development.
- Prototype/sample manufacturing and trials.
- Process validation and capability improvement.
- APQP/PPAP documentation and customer approval.
- Successful launch into SOP/serial production.

The candidate shall effectively coordinate with Production, Tool Room, Quality, Purchase, Maintenance, Suppliers, and other cross-functional teams.

Educational Qualification

- B.E./B.Tech in Mechanical Engineering, or
- Diploma in Mechanical Engineering

Additional qualifications or training in Tool & Die Design, Forging Technology, CAD/CAM, GD&T;, or Automotive Quality Systems will be an added advantage.

Experience

5 to 12 years of relevant experience in hot forging industries die development and new product development.

The candidate should preferably have hands-on experience in:

- Hot forging of automotive or engineering components.
- Forging process development and process parameter optimization.
- Forging die, punch, mandrel, trimming, and other tooling design.
- Design and development of jigs, fixtures, work-holding systems, and inspection gauges.
- Development of forged and machined components from prototype to serial production.
- Forging and machining trials, process prove-out, and validation.
- Coordination with die/tool manufacturers and external machining or tooling suppliers.
- Automotive or precision engineering component manufacturing.

Preferred Industry Background:
Hot Forging / Precision Forging / Engineering Manufacturing.

Key Responsibilities

- Review customer drawings,



specifications, RFQs, and customer-specific requirements for technical feasibility and manufacturability.
- Develop optimum manufacturing routes for hot forged and machined components.
- Define forging processes, billet size, heating requirements, forging sequence, flash requirements, trimming, and subsequent machining operations.
- Develop concepts for forging dies, punches, mandrels, trimming tools, sizing/coining tools, and other process tooling.
- Support the design, development, procurement, and validation of forging dies and tooling.
- Define machining processes, operation sequences, cutting tools, jigs, fixtures, work-holding systems, and inspection requirements.
- Coordinate with Tool Room and external tooling suppliers for die manufacturing, trials, modifications, and timely delivery.
- Support prototype and sample development, including forging trials, machining trials, process prove-out, and validation.
- Optimize forging and machining processes to achieve required dimensional accuracy, metallurgical properties, productivity, and cost targets.
- Identify opportunities for material yield improvement, cycle-time reduction, die life improvement, machining productivity, and manufacturing cost reduction.
- Troubleshoot forging defects, die-related problems, machining issues, and dimensional variation during product development and production ramp-up.
- Coordinate with Production, Quality, Tool Room, Purchase, and suppliers to ensure adherence to project milestones.
- Ensure the readiness of forging dies, machining fixtures, gauges, process parameters, and inspection methods before SOP/serial production.
- Support preparation and review of Process Flow Diagrams, PFMEA, Control Plans, work instructions, and other development documentation.
- Support APQP, PPAP, trial validation, capability studies, and customer approval activities.




- Participate in design and process reviews and implement actions to mitigate manufacturing and quality risks.
- Drive standardization and continuous improvement of forging tooling, machining fixtures, and manufacturing processes.
- Ensure compliance with applicable automotive quality systems, engineering standards, and customer-specific requirements.

Technical Competency

The candidate should possess strong technical competency in:

Hot Forging

- Hot forging process principles and process development.
- Billet size calculation and material flow considerations.
- Forging sequence development, including preforming, blocker, and finisher operations, where applicable.
- Knowledge of forging dies, punches, mandrels, inserts, trimming, sizing, and coining tools.
- Die material selection, die life improvement, and die maintenance considerations.
- Forging temperature and process parameter optimization.
- Understanding of common forging defects and their root-cause analysis.
- Knowledge of grain flow and the influence of forging processes on component quality.

Engineering & Tool Design

- Solid knowledge of engineering drawings, GD&T;, tolerances, fits, datums, and surface-finish requirements.
- Understanding of tolerance stack-up and datum schemes for forged and machined components.
- Proficiency in AutoCAD, SolidWorks, or equivalent CAD software.
- Knowledge of basic process simulation or forging simulation software will be an added advantage.
- Familiarity with structured problem-solving tools such as 5 Why, Fishbone Diagram, 8D, and Pareto Analysis.

Preferred Standards and Knowledge

The candidate should preferably have knowledge of:

- IATF 16949 – Automotive Quality Management System.
- APQP – Advanced Product Quality Planning.
- PPAP – Production Part Approval Process.
- PFMEA – Process Failure Mode and Effects Analysis.
- Process Flow Diagrams and Control Plans.
- MSA – Measurement System Analysis.
- SPC – Statistical Process Control.
- GD&T; standards and engineering drawing interpretation.
- Basic understanding of material specifications, heat treatment, hardness, and metallurgical requirements for forged components.

📌 Assistant Manager - Design (South India)
🏢 Amara Raja Group
📍 South India