Senior Component Engineer

Job Title : Component Development Manager – Forging & Machining

Functional Area : Component Development – Forging & Machining

Reporting : Functional reporting to : Divisional Head (CD F&M)

Educational Qualification

Desirable : B.Tech / M.Tech in Mechanical Engineering from IIT / NIT

Experience

Minimum : 5 years - 13 years

Job Role & Responsibilities

Role : Component Development – Gears and Shafts

Key Responsibilities :

1. Development & DFM Closure

Development of gears and shafts through hot & cold forging at vendor locations.

Study part drawings for feasibility and close DFM comments with R&D and vendors.

Prepare initial feasibility reports including forging dies, cold forging tool design, tonnage calculations, and forging simulation studies.

2. Vendor Support & Project Execution

Identify, select, and develop potential vendors (T1 & T2).

Conduct RFQ feasibility studies, prepare comparative charts, and finalize vendors.

Provide technical support for tooling, SIR, and process improvements.

Plan and execute development plans within timelines at vendor locations, resolving constraints, risks, bottlenecks, and quality issues.

Prepare and review process documents such as PFMEA, PFC, Process Sheets (IPO), SPC, MSA, FTG, FPIR.

3. Techno-Commercial Estimation

Prepare techno-commercials using zero-based costing.

Calculate cycle time for CNC, VMC, and other applicable processes.

4. Capacity Enhancement & Process Optimization

Conduct process improvement analysis and enhance vendor capacity.

Prepare budgets and techno-commercial synthesis with vendors.

Competency Requirements

Technical / Functional :

In-depth understanding of forging and gear machining processes.

Hands-on experience in : hot forging, cold forging, CNC, VMC, broaching, hobbing, shaping, shaving, teeth grinding, teeth honing, bore honing, and heat treatment of gears & shafts.

Knowledge of automotive standards (DIN / JIS) and gear microgeometry interpretation.

Proficient in GD&T, tolerance stack-up analysis, AutoCAD, Unigraphics, Kisssoft, ForgeNXT, and MS Office.

Strong troubleshooting, problem-solving, and process improvement capabilities.

Experience in technical & cost benchmarking, VA / VE, and alternate sourcing.

Behavioral / Soft Skills :

Excellent communication, negotiation, and interpersonal skills.

Strong analytical, team-building, and relationship management capabilities.

Positive, flexible, and solution-oriented attitude.

Preferred Candidate

OEM component development and R&D proto shop experience.

Candidates from leading 2W / 4W manufacturers or similar organizations.