: Toolroom Manager (Press Tools / Sheet Metal Stamping)

Reports to: Head of Operations / CEO

Direct reports: Press tool designers, toolmakers (fitters), wire EDM / VMC / grinding operators, die maintenance technicians

Location: Hosur

Purpose

Deliver press tools that make good parts at rated SPM, run for their designed stroke life, and cost the least per part. Own the tool from design review through build, try-out, production support, maintenance and retirement.

Key Responsibilities

1. Tool feasibility and design (stamping-specific)

- Review part drawings and 3D data for stampability: pierce and bend positions, edge distances, minimum bend radii, grain direction, burr direction, flatness and springback.
- Own strip layout and material yield decisions: pitch, carrier and web design, pilot strategy, stage count and scrap-cutting.
- Approve die designs for progressive, compound, blanking, piercing, bending, forming and drawing tools, including clearance by material and thickness, tonnage and centre of pressure, stripper design and scrap and slug removal.
- Check every design against the target press: shut height, bolster and slide size, stroke, SPM, knock-out and cushion availability, and feed length.
- Approve the BOM, standard parts (Misumi or equivalent), spring selection and die steel/heat treatment (D2/SKD11, carbide, coatings) before release.

2. Tool build and try-out

- Plan loading of wire EDM, jig grinding, VMC, surface grinding and bench fitting against delivery dates. Track every build with stage-wise milestones.
- Run try-outs with a documented process window: feed, pilot release, lubrication, stripper settings and shut height. Hand over to production with a setup sheet.
- Support sample submission, FAI and PPAP dimensional and burr/flatness requirements. Target approval within two trials.
- Decide make-versus-buy and manage outside vendors for heat treatment, die sets, coatings and overflow machining.

3. Die maintenance and tool life





- Maintain a tool register for every die: stroke count, last sharpening, shut height, tonnage, press allocation, spare list and location.
- Run preventive maintenance and sharpening schedules based on strokes, not calendar time. Set grind-allowance and refurbishment limits.
- Cut die-related press stoppages (punch breakage, galling, slug pulling, misfeeds, stripper and spring failures) through root-cause analysis (5-Why, 8D) and design-out fixes.
- Hold critical spares (punches, buttons, springs, pilots, inserts) so no die waits for a part.

4. Quality and customer support

- Keep tools producing parts within dimension, burr height, flatness and cosmetic limits. Give fast containment and corrective action on customer complaints.
- Supervise checking fixtures and gauges, and ensure calibration and MSA are current.
- Keep tool and gauge records audit-ready for IATF 16949 / ISO 9001 and OEM supplier audits.

5. Cost reduction and improvement

- Reduce tooling cost through standard die sets, modular and common components, fewer stages and shorter build hours.
- Improve material utilisation, die life and rework rates.
- Drive quick die change (SMED), and support IoT stroke counting and die-protection sensors for tool-life tracking.
- Introduce CAD/CAM and forming simulation where it reduces try-out iterations.

6. People and safety

- Hire, train and mentor designers and toolmakers. Maintain a skill matrix and cover for key skills.
- Enforce die handling, lockout, safe lifting, tool storage and 5S rules.
- Set explicit KPIs, review weekly, and report monthly to management.





Qualifications and Experience
- Diploma or B.E./B.Tech in Mechanical / Tool & Die / Production Engineering. CIPET/NTTF tool-design certification is a plus.
- 10–20 years in press tool design and manufacture, with 4–5+ years leading a toolroom, preferably in automotive Tier-1/Tier-2 stamping.
- Proven record on progressive dies in 1–6 mm HR/CR steel. Stainless, aluminium or high-strength steel experience is a plus.
- Experience with mechanical C-frame and straight-side presses in the [80–800 T] range.

Technical Skills
- Strip layout, die clearance, tonnage, springback and bend allowance calculations.
- Wire EDM, jig grinding, VMC and bench fitting. Practical knowledge of heat treatment and surface coatings.
- CAD (SolidWorks / CATIA / NX / AutoCAD) and CAM. Forming simulation (AutoForm or similar) preferred.
- Die protection, sensors, feeders, straighteners and die cushion/knock-out systems.
- APQP, PPAP, FMEA, control plans, MSA and SPC.

Behavioural Competencies
- Hands-on and decisive. Comfortable on the shop floor and at the customer table.
- Methodical root-cause problem solver under delivery pressure.
- Works closely with design, production, quality, purchase and customers.
- Ownership of cost, delivery and safety.

KPIs KPITargetOn-time tool delivery vs. committed date 90%Tools approved within 2 trials 80%Tool-related press downtime (% of press hours)Reduce year on yearStrokes between major refurbishmentsMeet design targetTooling cost vs. budgetWithin 5%Repeat customer complaints from toolingZeroPreventive maintenance adherence 95%Material utilisation on new toolsAt or above quoted yield

Compensation

Job Requirements :

- 10-20 years of experience in a similar role in the auto components industry.
- Proficiency in Tool-Design certification or equivalent qualification.
- Strong knowledge of press tool design, die making, wire EDM, VMC machine operation.

📌 Tool Room Manager (Hosur)
🏢 Veritas Engineering
📍 Hosur