Deputy Manager - Process Engineering and Tooling Quality

Mahindra And Mahindra Limited; Chakan; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Mahindra & Mahindra Limited invites applications for Dy. Manager- PE & Tooling Quality to lead formability analysis, CAE simulations, and defect countermeasures across BIW manufacturing.

The role requires coordinating with customers and internal teams to validate processes for new model introductions on existing lines. You will develop BIW process plans for manual and robotic welding, build robotic welding simulation cells and OLP, and create standards for simulation and OLP while driving

Qualifications

• 2 to 8 years of BIW Manufacturing, Production or Assembly experience.
• Bachelors in Mechanical or Automobile Engineering or a Diploma in Mechanical/Automobile.
• Experience with BIW processes, robotics welding, and cycle time optimization.

Responsibilities

• Formability analysis of sheet metal parts.
• Simulation with CAE software (Auto Form / Pam Stamp).
• Suggest counter measures for defects.
• Interact with customer and resolve concerns.
• Manufacturing feasibility study for new model introduction on existing line.
• Develop BIW process plans for manual and robotic welding lines.
• Develop BIW robotic welding simulation cells and OLP.
• Generate standards and check sheets for simulation and OLP.
• Collaborate with CME process, PLC and Line builders for verification of Simulation and OLP during DAP and trials at suppliers.
• Installation and commissioning with post SOP support for Process and cycle time prove out.
• Line layout, Manufacturing process flow, Cycle time chart and RFQ preparation of BIW sub assembly.
• Do process study wrt gun, equipment, fixtures and suggest suitable changes in product to ensure first time right manufacturability.
• Build up the station/cell/line in PS by adding all relevant resources.
• Check for Gun reachability, apply all kinematics to relevant tools and create robot path with zero collision with basic tools.
• Generate Basic path (welding, tip dressing, etc) and zoning conditions to avoid any collision.
• Collaborate and Coordinate with Line builders to get the line simulation done and optimize the robot paths, robot zoning and again give feedback for any improvement required in design.
• Hands on experience of virtual controller such as- ABB / Fanuc / KUKA etc, generate the OLP with the cycle time accuracy of 99%.
• Find out root causes to achieve cycle time targets if not achieved.
• Ensure Zero error / collision / losses through continuous involvement with execution team.

Skills

BIW Manufacturing

Robotic welding

Simulation & CAE

Process optimization

Education

Bachelor of Technology in Mechanical / Automobile

Diploma in Mechanical / Automobile

Tools

ABB/Fanuc/KUKA robots

Robot path planning

Job description

Dy. Manager- PE & Tooling Quality Responsibilities & Key Deliverables

• Formability Analysis of Sheet Metal Parts.
• Simulation with CAE Software ( Auto Form / Pam Stamp).
• Suggesting Counter measures for the Defects.
• Interaction with customer and Concern Resolution.
• Manufacturing feasibility study for new model introduction in existing line.
• Develop BIW process plans for Manual and Robotic welding Lines.
• Develop BIW Robotic welding simulation cells and OLP in PS Team center / standalone.
• Generate standards and check sheets for Simulation and OLP through benchmarking and lessons learnt.
• Collaborate with CME process, PLC and Line builders for verification of Simulation and OLP during DAP and trials at suppliers.
• Installation and commissioning with post SOP support for Process and cycle time prove out.
• Line layout, Manufacturing process flow, Cycle time chart and RFQ preparation of BIW sub assembly.
• Do process study wrt gun, equipment, fixtures and suggest suitable changes in product to ensure first time right manufacturability.
• Build up the station/cell/line in PS by adding all relevant resources.
• Check for Gun reachability, apply all kinematics to relevant tools and create robot path with zero collision with basic tools.
• Generate Basic path (welding, tip dressing, etc) and zoning conditions to avoid any collision.
• Collaborate and Coordinate with Line builders to get the line simulation done and optimize the robot paths, robot zoning and again give feedback for any improvement required in design.
• Hands on experience of virtual controller such as- ABB / Fanuc / KUKA etc, generate the OLP with the cycle time accuracy of 99%.
• Find out root causes to achieve cycle time targets if not achieved.
• Ensure Zero error / collision / losses through continuous involvement with execution team.

Preferred Industries Automotive Industry Manufacturing Education Qualification Bachelors of Technology in Mechanical / Automobile Diploma in Engineering in Mechanical / Automobile General Experience 2 to 8 years of relevant experience in BIW Manufacturing, Production, Assembly. Experience Level Mid Level