Development Engineer - ( NPD - Plastic )

Feasibility review of parts

Stagewise process design for injection & blow molding process

Manufacturing lead time and cost estimation for injection & blow molds

Prepare Quality plan for product development

Approval of injection & mold design (back up calculations to meet the part dimensions, mold construction, molding machine selection)

Manufacturing of tool / fixture / inspection gauge

Track the project progress for mold development

Part optimization planning

Conduct stage wise PPAP

Continual improvements in processes to improve upon Quality, cost & delivery

Injection & blow molded part design review

Various plastic raw materials and its processing requirements

Conceptualize tool design (2 plate mold, 3 plate molds, HRS systems, various gating considerations, insert molding, sliders, cams, 2 stage ejector systems)

Injection & blow molding Process understanding (part wall thickness, drafts etc.)

Process flow for injection & blow molded parts

Process flow diagram (PFD)

Major elements contributing to tool making lead time, its manufacturing processes

Costing of tool elements & mold manufacturing processes

Understanding flow simulation reports and its use for concept design

PEMEA

Types of molds, mold construction

Tonnage calculation; molding machine selection

Cycle time estimation

Raw material processing conditions & limitations

Mold design Checklist

Manufacturing process for molds, machining elements, heat treatment.

Mold assembly

Mold Inspection & approval

Prepare detail mold manufacturing plan

Periodic review and update the progress

Mold inspection at various stages of manufacturing

Mold tryout and troubleshooting

Injection & blow molding process parameter understanding

Review of part inspection reports and plan for optimization

Review assembly feedback, corelate with the part dimensions and action plan for improvements

Awareness of IATF system

Quality documents APQP, FMEA, PPAP, SPC, MSA

Problem solving techniques

SPC

TGR, TGW

Use of process understanding to develop parts of expected quality with min cost & min time to develop the part

Use of process understanding for process design

Use of the toolmaking process steps for time and cost estimation

Use product and process knowledge to build P FMEA for mold and molding process

Use of knowledge to make molds to produce expected quality of parts

To make product defect free

To ensure project completion with the agreed due dates

To ensure project completion with the agreed due dates

PPAP approval for the parts under development

Understand

Data Collection,

Observations,

Patterns through observations