Job Title: Senior Design Engineer Hot Forging (NPD)
Experience: 46 Years
Location: Chennai (Appur / Sriperumbudur TN)
Reporting to: Head of Engineering / Plant Head

Job Purpose:
The Senior Design Engineer will lead end-to-end New Product Development (NPD) projects from concept and die design through to successful shop-floor implementation. The role demands knowledge of simulation to help improve design and reduce trial-and-error, along with strong practical leadership to coordinate with Tool Room, Quality, Production and Maintenance teams for effective execution

Key Responsibilities:
1. Design & Simulation (The Core Technical Role):
Design closed-die forging sequences for complex automotive and industrial components using CAD (AutoCAD/SolidWorks/CATIA).
Creative Pre-forming: Develop innovative pre-form (blocker) designs to ensure optimal metal flow, reduce flash percentage, and prevent common defects like laps or cold shuts.
Advanced Simulation: Execute virtual trials using Q-Form or DEFORM-3D to validate grain flow, thermal load on dies, and load requirements.
Perform analysis of material yield across product families/portfolio to identify high-waste parts for redesign.
2. Cross-Functional Liaison (The Execution Lead):
Tool Room Coordination: work with the tool room lead for die manufacturing, ensuring that CNC programs and EDM processes align strictly with design tolerances and standards.
Maintenance Partnership: Act as the technical bridge to the Maintenance Lead. Work together to troubleshoot press related issues that affect the quality of the forged part.
Shop Floor Trials: Lead physical trials on the floor, collecting real-time data to "close the loop" between simulation results and actual forging results.
Quality improvement: work closely with the head of quality and production to address any die related and other quality issues in the forgings
3. Process Improvement (NPD & Current Jobs):
Review existing "problem jobs" and propose design modifications (revised draft angles, fillet radii, or lubricant application) to increase die life and reduce rejection rates.
Standardize tooling components to reduce the spare parts inventory handled by the maintenance department.
Required Candidate Profile:
Education: B.E./B.Tech in Mechanical or Production Engineering.
Experience: 4-6 years in a Hot Forging setup with design experince.
Software Proficiency: Candidates with high proficiency in Q-Form or DEFORM-3D. and mandatory: 3D Modeling (SolidWorks/NX) preferred
Technical Skills: Forging, preform design knowledge and deep understanding of material behaviour at high temperatures (Steel/Alloy/Micro-alloy) along with heat treatment
o Overall familiarity with hot forging equipment
o Knowledge of post forging machining and surface treatment processes
Behavioural Competencies: * Diplomatic Leadership: Ability to work with cross functional teams and practical shop-floor leads without friction.
o Ownership: Goal oriented attitude toward pushing NPD projects through any bottlenecks

Key Performance Indicators (KPIs):
1. Lead Time Reduction: Shrinking the time from design to "First Time Right" (FTR) sample.
2. Yield Optimization: Achieving target weight reductions through creative pre-forming.
3. Die Life Improvement: Percentage increase in average hits per die set.
4. Audit Compliance: Successful implementation of efficiency improvements (e.g., air leak rectifications identified in energy audits).

Senior Design Engineer Hot Forging

El Forge Ltd.

Job Description

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