New Product Development Manager

Roles and Responsibilities :

1. Technical Feasibility & Design for Manufacturability (DFM)

• Feasibility Studies: Review customer 2D/3D component drawings, GD&T, and material specifications (e.g., high-strength steels, CRCA, stainless, copper/brass alloys).
• Forming Simulation Review: Analyze forming simulation reports (AutoForm, Dynaform, or PAM-STAMP) to predict thinning, wrinkling, springback, and splits.
• Cost & Scrap Optimization: Suggest part modifications to optimize strip layout, nesting efficiency, pitch, and minimize tonnage requirements without compromising product function.

2. Tooling & Die Development Strategy

• Die Concept & Process Routing: Define tool architecture (progressive dies, transfer dies, stage/compound tooling) and secondary operations (piercing, tapping, deburring, plating, projection/spot welding).
• Tool Procurement & Vendor Management: Prepare tool specifications, float RFQs to internal tool rooms or external toolmakers, evaluate technical bids, and monitor manufacturing milestones.
• Die Tryouts & Commissioning: Lead T0, T1, and subsequent die tryouts; systematically resolve stamping defects such as burrs, edge tear, mismatch, twist, and dimensional drift.

3. APQP, Quality Systems & Customer Approvals

• APQP Gateway Management: Drive Advanced Product Quality Planning stages (Phase 1 to Phase 5) to ensure on-time delivery across all milestones.

• Core Tool Documentation: Develop and validate the Process Flow Diagram (PFD), Process Failure Mode and Effects Analysis (PFMEA), and pre-launch Control Plans.

• PPAP Delivery: Oversee submission of Production Part Approval Process packs up to Level 3/4/5, including:

  • Full dimensional layout inspection (CMM/scanning).
  • Measurement System Analysis (MSA / Gage R&R) for checking fixtures.
  • Statistical Process Control (SPC / $C_p, C_{pk} \ge 1.67$) on critical-to-quality (CTQ) dimensions.
  • Raw material test certificates (chemical, mechanical, grain structure).

• Checking Fixtures (CF/Panel Gages): Design, procure, and calibrate Go/No-Go gages and CMM holding fixtures alongside tool manufacturing.

4. Cross-Functional Execution & Handover

• Capacity & Press Allocation: Match tool bolster dimensions, shut height, feed line parameters, and required press tonnage (mechanical, hydraulic, or servo presses) with plant capacities.
• Pilot Batches (Run@Rate): Conduct pilot runs at nominal production speeds to prove process capability, cycle time, scrap rate, and OEE targets.
• Serial Production Handover: Formally sign off tool handover to Operations and Maintenance, delivering preventive maintenance SOPs, spare part lists (punches, die buttons, gas springs), and work instructions.

5. Costing, Timeline & Customer Interface

• Project Tracking: Maintain the Master Timing Plan (Gantt chart), identify critical paths, and mitigate schedule slippages against SOP (Start of Production) deadlines.
• Tooling Budget Control: Manage Capex budgets for dies, checking fixtures, and ancillary automation (uncoilers, straighteners, servo feeders).
• Technical Interface: Act as the primary technical contact for customer engineering and quality teams during technical reviews, plant audits, and design changes (ECN/ECR management).

Job Requirements :

• 10-20 years of experience in new product development in the Sheet Metal Stamping industry.
• Strong understanding of Tool engineering principles and processes.
• Proven track record in developing innovative products that meet customer needs and drive business growth.
• Experience in sheet metal development, stamping, manufacturing, and product development is advantageous.
• Ability to manage multiple projects simultaneously and prioritize tasks effectively.
• Strong communication and collaboration skills are essential.