Design and Development Engineer

About the Role

We are seeking a proficient Design and Development Engineer to spearhead the design, development, and industrialization of sheet metal and tubular parts, intricate assemblies, tooling, and fixtures in the automotive sector. The position is based at LK Automotive Pvt Ltd in Makarpura GIDC, Vadodara, Gujarat.

Key Responsibilities

• Lead the entire design and development process of sheet metal and tubular components and complex assemblies from concept stage to production release.
• Create and revise 3D models, 2D drawings, assemblies, and production documentation utilizing SolidWorks software.
• Design tools for hydraulic and mechanical presses covering all sheet metal operations such as forming, bending, blanking, and deep drawing.
• Develop various fixtures including welding, checking/inspection, assembly, and production/process fixtures.
• Design tooling and processes with consideration for design for manufacturing/assembly (DFM/DFA), cost-efficiency, cycle time, dimensional accuracy, and quality standards.
• Apply in-depth knowledge of sheet metal manufacturing processes including laser cutting, press punching, blanking, bending, forming, deep drawing, and welding/fabrication.
• Operate and program CNC 3-axis pipe bending machines with a thorough understanding of tooling, bend sequencing, and troubleshooting.
• Develop and optimize tubular components and bending processes.
• Interpret and apply engineering drawings, GD&T principles, tolerances, material specs, and customer mandates.
• Manage welding process development by understanding welding symbols, procedures, sequences, and quality requirements.
• Support development and optimization of welding fixtures to guarantee dimensional accuracy and reproducibility.
• Collaborate with departments such as Production, Quality, Purchasing, and Tool Room for new product development and process rollout.
• Conduct tooling and fixture trial runs, diagnose issues, and implement corrective measures.
• Assist with prototype creation, sample submissions, PPAP, APQP, FMEA, Control Plan documentation, and related process documentation.
• Analyze quality problems linked to development and design/process improvements effectively.
• Ensure all design and development activities adhere to IATF 16949 and customer-specific standards.
• Communicate with customers for clarifications, design amendments, and technical approvals.
• Manage multiple projects, timelines, tooling needs, and engineering deliverables simultaneously.
• Identify and execute opportunities to reduce cost, improve processes, shorten cycle times, and enhance productivity.

Required Technical Expertise

• Proficient with SolidWorks for 3D modeling, sheet metal and assembly design, 2D drawings, and design revisions.
• Strong familiarity with tool design for hydraulic and mechanical presses.
• Solid understanding of GD&T, engineering drawings, tolerances, and fits.
• Comprehensive knowledge of sheet metal manufacturing techniques including laser cutting, punching, blanking, bending, forming, deep drawing, and press operations.
• Hands-on experience with CNC 3-axis pipe bending machines, including operation and programming.
• Expertise in tubular component fabrication and development.
• Knowledge of welding symbols, sequences, parameters, fixtures, and quality standards, and ability to troubleshoot related fixtures and processes.
• Skilled in design and troubleshooting of a range of fixtures: hydraulic/mechanical press tooling, welding, checking, assembly, and production/process fixtures.
• Competence in Microsoft Office Suite including Excel, Word, and PowerPoint for preparing technical and project reports.

Preferred Knowledge Areas

• Understanding of IATF 16949 automotive quality standards.
• Experience with APQP, PPAP, DFMEA/PFMEA, Control Plans, MSA, SPC, and root cause analysis (8D).
• Familiarity with automotive component development and customer specific requirements.
• Ability to estimate tooling and fixture costs.

Candidate Profile

• Diploma or Bachelor’s degree in Mechanical Engineering or equivalent.
• 5 to 10+ years of relevant experience in sheet metal, tubular components, automotive parts, or fabrication industries.
• Strong practical experience in manufacturing processes and tooling beyond theoretical design knowledge.
• Ability to independently manage new product developments from design review through production launch.
• Excellent problem-solving, analytical, communication, and team leadership abilities.
• Competent at coordinating with customers, suppliers, production, quality control, and tool room personnel.
• Hands-on approach to identify and resolve manufacturing issues effectively at the shop floor level.

Performance Indicators

• Timely delivery of new product developments.
• Successful development and trial of tooling and fixtures.
• Reduction in development and tooling-related defects and issues.
• Improvements in product quality and dimensional accuracy.
• Optimized cost and reduced cycle time.
• Effective engagement and coordination with customers.
• Compliance with IATF 16949 standards.
• Smooth transition from development phase to mass production.