Senior Process Engineer ( NPD )

ideaForge; Navi Mumbai; On-site; INR 900,000 - 1,300,000; Full time

Job summary

ideaForge is seeking a Manufacturing NPD engineer to lead New Product Development and Industrialization, ensuring smooth transition from design to mass production. You will drive DFMs, process validation, tooling, and capacity planning while coordinating with Engineering, Quality, Supply Chain and Operations.

You will develop and implement manufacturing flow charts, PFMEA, SOPs, and setup for prototype, pilot builds, and production ramp-up, ensuring readiness before SOP and sustaining continuous

Qualifications

• Bachelor's degree / Diploma in Mechanical, Electrical, Electronics, Mechatronics, Industrial Engineering or related engineering discipline.
• 2–3 years of relevant experience in NPD, Manufacturing Engineering, Production Engineering, Industrialization or Process Engineering.
• Experience in prototype development, pilot builds, product industrialization and production ramp-up.
• Strong analytical, project management and cross-functional coordination skills.

Responsibilities

• Analyse, develop, implement, and maintain manufacturing processes, operation sequences, specifications, equipment requirements, and manufacturing flow for new and existing products.
• Act as the Manufacturing/NPD representative in New Product Development teams, working closely with Design Engineering, Quality, Supply Chain, V&V and Operations from concept to production release.
• Plan and execute prototype, Engineering Build, Pilot Build and Production Ramp-up activities, ensuring timely closure of manufacturing and process-related issues.

Skills

Analytical skills

Project management

Cross-functional collaboration

Process improvement

Problem-solving

Attention to timelines

Education

Engineering degree/diploma

Tools

AutoCAD

ERP/PLM systems

Job description

Job Description

• This position will be responsible for New Product Development (NPD) and Industrialization activities, ensuring that new products are successfully transitioned from Engineering design to stable production. The role will involve manufacturing feasibility, DFM/DFA reviews, prototype and pilot builds, process development, tooling and fixture development, BOM and drawing readiness, process validation, production ramp-up, and cross-functional coordination with Engineering, Quality, Supply Chain and Operations.
• The position will be responsible for ensuring product and process readiness before SOP, identifying and resolving manufacturing challenges during NPD, establishing robust manufacturing processes, and driving continuous improvement during the transition to mass production.
• Typical duties include NPD planning and execution, DFM/DFA, process feasibility, prototype build management, manufacturing process development, tooling and fixture development, equipment qualification, process validation, ECN implementation, PFMEA, Control Plan, SOP, Work Instruction, Job Card, capacity planning, line balancing, pilot production, yield improvement and production ramp-up.

Key Responsibilities

• Analyse, develop, implement, and maintain manufacturing processes, operation sequences, specifications, equipment requirements, and manufacturing flow for new and existing products.
• Act as the Manufacturing/NPD representative in New Product Development teams, working closely with Design Engineering, Quality, Supply Chain, V&V and Operations from concept to production release.
• Conduct DFM/DFA, process feasibility and manufacturability reviews during the product design stage and provide inputs on design, material, tolerance, assembly sequence, tooling and process requirements.
• Plan and execute prototype, Engineering Build, Pilot Build and Production Ramp-up activities, ensuring timely closure of manufacturing and process-related issues.
• Ensure readiness of BOM, drawings, specifications, process documentation and manufacturing requirements before commencement of prototype and production builds.
• Develop and implement Manufacturing Flow Charts, Standard Work, Process Control Plans, PFMEA, SOPs, Work Instructions, Job Cards and Setup Approval documents as per ISO and IdeaForge standards.
• Identify, develop and validate jigs, fixtures, tooling, gauges and small automation required for new product assembly and manufacturing.
• Drive Equipment Qualification and Process Qualification, including equipment trials, process capability studies and periodic validation of critical tooling and processes.
• Troubleshoot manufacturing and assembly issues during NPD builds and implement sustainable corrective and preventive actions using structured problem-solving methodologies such as 5-Why, 8D, DMAIC and Fishbone analysis.
• Implement engineering and process changes through the ECN/ECR process, ensuring proper impact assessment, documentation, validation and implementation at production.
• Develop capacity plans, line balancing, manpower requirements, cycle-time estimates and production layouts to support successful production ramp-up.
• Coordinate with suppliers for tooling, fixtures, equipment and process development, including technical evaluation, trials, supplier selection, installation and qualification.
• Monitor build quality, FPY, rejection, rework, cycle time and process capability during prototype and pilot builds and drive improvements before SOP.
• Support the resolution of customer concerns, field issues and production-related failures through structured analysis and implementation of corrective actions.
• Support and participate in customer audits, process audits and Quality System audits, ensuring NPD processes and documentation meet applicable requirements.
• Ensure effective knowledge transfer from NPD to Operations/Production through defined handover processes, training, documentation and process validation.

Functional Competencies

• Strong understanding of New Product Development, Product Industrialization and Manufacturing Readiness processes.
• Ability to conduct Process Feasibility, DFM/DFA reviews, Process Flow preparation and manufacturing risk assessment.
• Good understanding of GD&T, tolerance stack-up, engineering materials, assembly methods, DFM/DFA, ergonomics and Poka-Yoke principles.
• Ability to conceptualize, design and develop efficient jigs, fixtures, gauges and tooling, including automation wherever feasible.
• Ability to plan and execute prototype, pilot and production builds, including build readiness, issue tracking and closure.
• Ability to develop and implement PFMEA, Control Plans, SOPs, Work Instructions, Job Cards and Standard Work.
• Hands-on knowledge of process planning, line balancing, capacity planning, cycle-time improvement and production ramp-up.
• Knowledge of equipment selection, supplier evaluation, technical feasibility, quotation evaluation, equipment trials, installation and qualification.
• Ability to conduct process capability studies, MSA, SPC and other statistical/process monitoring techniques as required.
• Ability to identify opportunities for process improvement, cost reduction, automation and productivity improvement without compromising quality or reliability.
• Strong understanding of ECN/ECR implementation and change management, including impact assessment and validation.
• Ability to coordinate and work effectively with Design Engineering, Quality, Supply Chain, Production, V&V and external suppliers to achieve NPD milestones.
• Hands-on experience with problem-solving tools such as 5W-1H, 5-Why, Fishbone, 8D, DMAIC and Root Cause Analysis.
• Basic knowledge of drafting/design software such as AutoCAD or equivalent CAD tools.
• Good understanding of ERP/PLM systems, BOM management, drawing release and engineering documentation.

Skills & Qualification

• Degree/Diploma in Mechanical, Electrical, Electronics, Mechatronics, Industrial Engineering or a related engineering discipline.
• 2-3 years of relevant experience in New Product Development, Manufacturing Engineering, Production Engineering, Industrialization or Process Engineering.
• Experience in prototype development, pilot builds, product industrialization and production ramp-up.
• Strong analytical, project management and cross-functional coordination skills.
• Hands-on experience in manufacturing/process development, tooling, fixtures and process validation.
• Experience in engineering change management, process documentation and production handover

Key Shared Accountabilities

• Customers
• Competence to understand and effectively address customer requirements and concerns by ensuring product quality, manufacturing readiness and timely resolution of issues.
• Business Team
• Work closely with Engineering, Operations, Quality, Supply Chain, V&V and other functions to ensure successful and timely execution of NPD projects while maintaining strong cross-functional relationships.
• Work closely with suppliers for tooling, equipment, fixtures, process development and industrialization, ensuring technical capability, quality, cost and delivery requirements are met.
• Operations
• Ensure a smooth transition of new products from Engineering/NPD to Production, with complete process documentation, validated processes, trained manpower, approved tooling and defined production standards.

Desired Behavioural Values

• Commitment to common purpose and goals
• Respect for people and collaboration
• Displaying integrity and ethics
• Taking initiative and ownership
• Strong problem-solving and analytical mindset
• Being passionate about making a difference
• Customer and product-focused approach
• Ability to work effectively in a fast-paced NPD environment
• Execution-oriented approach with strong attention to timelines
• Willingness to challenge existing processes and drive continuous improvement
• Maintaining discipline in documentation, process adherence and engineering change management