New Product Development

The New Product Development Engineer

SGGPL is one of the leading manufacturers and suppliers of a wide range of transmission gears, engine gears and shafts to the agricultural automotive equipment. We earnestly aim at having continual improvement in all our activities through proper implementation of systems, developing of people and processes and total approach to management of quality.

Job PurposeTo take new gear and shaft components from customer enquiry to stable regular production. The NPD Engineer studies drawings, plans the manufacturing process, arranges tooling and fixtures, runs trial lots, gets customer approval and hands over a proven process to the shop floor.

Key Responsibilities1. Enquiry and Feasibility•        Study customer drawings, specifications and 3D models, and check manufacturing feasibility.

•        Review gear data (module, number of teeth, pressure angle, helix angle, tolerance grade, profile and lead modifications, material and heat treatment).

•        Prepare cycle time, tooling cost and part cost estimates to support quotations.

•        Identify risks early and raise them with the customer before order confirmation.

2. Process Planning•        Prepare the process route, operation sheets and process flow diagrams for each new part.

•        Select suitable machines and processes: turning, hobbing, shaping, shaving, broaching, milling, drilling, deburring, heat treatment, and grinding or honing where required.

•        Set cutting parameters, set-ups and standard production quantities per shift.

•        Update standard production figures in the production planning records after trials.

3. Tooling, Fixtures and Gauges•        Design or specify hobs, shaper cutters, shaving cutters, broaches, inserts, fixtures, jaws and mandrels, and release purchase requests.

•        Coordinate with tool suppliers, fixture makers and the in-house tool room, and follow up on delivery dates.

•        Arrange gauges, master gears and inspection fixtures with the Quality department.

•        Monitor tool life and suggest improvements to reduce tool cost per piece.

4. Trials and Prototype Development•        Plan and run trial and prototype lots on the shop floor with production and maintenance teams.

•        Record trial results: cycle time, tool life, dimensional results, rejection and rework.

•        Fine-tune the process until it is stable and capable, then freeze it.

•        Prepare sample submission reports and take part in customer approvals.

•        Continuous monitoring the development and assuring delivery commitment of the customers are met.

5. Quality Planning and Documentation•        Prepare the control plan, PFMEA, process flow chart and inspection plan (PPAP/APQP documents where the customer requires them).

•        Work with Quality to define gear inspection requirements: profile, lead, pitch, runout, over-pins or span measurement, surface finish and hardness.

•        Support root-cause analysis (8D, 5-Why) for any problems found during development or in the first production lots.

6. Handover and Continuous Improvement•        Train supervisors and operators on the new process, set-up sheets and quality checks before production starts.

•        Stay available through the first production lots and fix start-up issues.

•        Look for cycle time reduction, tool cost savings and rejection reduction on existing parts.

•        Maintain a project tracker that shows each part's status, delays and open actions.

Qualifications•        Diploma or B.E./B.Tech in Mechanical, Production or Industrial Engineering.

Experience•        Minimum 5 years in new product development, process engineering or manufacturing engineering in a machining-based industry.

•        Gear manufacturing experience is preferred, especially in hobbing, shaping, shaving or broaching and in gear inspection.

•        Experience in automotive, tractor, two-wheeler or transmission components is an advantage.

Skills and KnowledgeTechnical•        Strong drawing reading and GD&T knowledge.

•        Good knowledge of gear terminology, gear types (spur, helical, splined shafts and cam shafts) and gear quality standards (DIN, ISO, AGMA).

•        Knowledge of CNC machining processes, cutting tools and cutting parameters.

•        Understanding of heat treatment (case hardening, induction hardening) and its effect on gear distortion.

•        Working knowledge of measuring instruments, gear testers and CMM reports.

•        Knowledge of APQP, PPAP, PFMEA, control plans and MSA.

•        CAD skills (AutoCAD / SolidWorks or similar) and good MS Excel skills.

Personal•        Analytical and problem-solving mindset, with a hands-on approach on the shop floor.

•        Good communication with customers, suppliers, production and quality teams.

•        Ability to manage several development projects at once and meet deadlines.

•        Ownership of results and good documentation discipline.

Key Performance Indicators•        On-time completion of new part development against the agreed schedule.

•        First-time sample approval rate.

•        Achievement of the standard cycle time and tool life targets.

•        Rejection and rework during trials and the first production lots.

•        Accuracy and completeness of process documents and records.

•        Opportunity to grow into a senior NPD, process engineering or manufacturing head role.