Head - Design & Development | Faridabad

BHATIA ALLOY FORGINGS PVT. LTD.
JOB DESCRIPTION
Position
Head – Design & Development (Forging Dies, Tooling & Process Engineering)
Department
Technology / Engineering
Reporting To
Chief Technical Officer (CTO)
Location
Faridabad, Haryana
Industry
Premium aluminium forging, heat treatment, machining and anodising
Role Level
Senior Leadership
About BAFPL
BAFPL manufactures premium lightweight aluminium forged, precision-machined and anodised components for demanding domestic and export automotive customers, including premium two-wheeler applications. Consistent quality, repeatable process capability, strong development-to-production handover and customer confidence are essential.
Role Objective
Own the end-to-end Design & Development function for premium aluminium forged and machined components: customer technical interpretation, product/process feasibility, forging die/tool/fixture design, process route engineering, trials, validation, design release and stable handover for commercial production. Ensure Design creates manufacturable, repeatable and cost-effective solutions.
Key Responsibilities
Customer Requirement & Product/Process Feasibility
· Own engineering translation of customer drawings, performance/cosmetic specifications, material grades, special characteristics and manufacturability requirements into robust technical concepts.
· Lead feasibility and design reviews with NPD, Quality, Manufacturing and Tool Room; flag capability, tolerance, surface-finish, cost and delivery risks before design freeze.
Forging Die, Tooling & Fixture Design
· Own forging die concept, preform/flash strategy where relevant, material flow, die steel/coating/heat treatment, die-life improvement and drawing/BOM/revision control.
· Lead design of machining fixtures, gauges, checking aids and tooling interfaces; validate clamping, datum strategy, repeatability and inspection accessibility.
· Use appropriate CAD/CAM and simulation (forging FEA/material flow, thermal/distortion, machining process verification) and translate findings into trials.
Process Design: Forging → Machining → Surface Finish
· Own process flow and technical route from raw material through forging, heat treatment, machining, washing/pre-treatment and anodising interfaces.
· Define CTQs, tolerances, machine/fixture requirements, parameter windows, critical process controls and reaction-plan inputs with process owners.
· Address forging-to-machining allowance, datum transfer, distortion, surface integrity, thread protection, dimensional capability and cosmetic finish requirements.
NPD Trials, Validation & Handover
· Lead Design/Development deliverables for prototypes, samples, trials, technical deviations, drawing freeze, tooling validation and engineering changes.
· Provide design/process inputs to PFMEA, Control Plan, APQP, PPAP, MSA, Cp/Cpk studies and Run-at-Rate; close design-originated risks before SOP.
· Deliver approved drawings, tool history, validated process sheets, setup standards, lessons learned and open-issue status to NPD/Manufacturing; support Safe Launch.
Team, Systems & Improvement
· Build a capable die/tool and process-design team, competency matrix, peer design reviews, technical standards, knowledge library and project tracking.
· Reduce die failure, rework, trial iterations, engineering change frequency and design-originated customer/production defects through structured RCA and design improvement.
· Partner with independent Quality for assurance and with Manufacturing for sustained execution; escalate unresolved technical risks to CTO.
Key Result Areas / KPIs
· First-time-right die/tool trials and development lead time
· Die life, tool-related scrap, trial iterations and tooling rework cost
· Process capability of critical characteristics at technical handover
· Design-related defects/engineering changes after SOP
· On-time drawing/tool release, technical documentation completeness and team skill development
Qualification & Experience
· B.E./B.Tech in Mechanical, Production, Manufacturing or Metallurgy; Diploma with exceptional relevant depth may be considered
· Typically 15–20 years in forging die/tool design and process engineering, with 5+ years leading design teams
· Hands-on aluminium forging die development and CNC machining process/fixture interface strongly preferred
· Evidence of independently taking multiple automotive parts from drawing through die trials to stable production
· Forging simulation/CAD-CAM, OEM drawing interpretation and premium surface-finish exposure desirable
Technical / Hard Skills – Must Have
· Forging die design, tool engineering, material flow, die-life and failure analysis
· 3D CAD and manufacturing drawings; forging simulation/FEA desirable; GD&T, tolerance stack-up and datum strategy
· Machining process planning, fixtures, gauges, CNC interface and forging-to-machining allowances
· DFM/DFA, technical risk review, PFMEA inputs, APQP/PPAP interfaces, validation, capability and change control
· Structured design reviews, trial problem solving, engineering documentation and project execution
Skills / Knowledge That Can Be Learned in 3–6 Months
· BAFPL-specific customer drawings and product families
· Specific machine platforms, die standards, CAD/PLM/ERP tools and internal reporting formats
· Specific anodising chemistry (must understand upstream surface impact and interface controls)
Leadership / Soft Skills & Cultural Fit
· Detail-oriented and rigorous, but open to shop-floor feedback
· Coaches designers, works collaboratively with Tool Room/NPD/Production/Quality
· Owns design errors and learns from failures; respectfully challenges unrealistic launch assumptions
Indicative DISC / Assessment Fit
Prefer strong analytical/conscientious (C) orientation with sufficient decisiveness (D), collaboration/influence (I) and stability/coaching (S). DISC is not a selection filter or validated predictor on its own; assess actual behaviour using structured interviews, case exercises and references.
First 90 Days – Expected Deliverables
· 0–30 days: audit die/tool design standards, top die failures, engineering changes and recent launch problems
· 31–60 days: implement design-review checklist, design-risk register, drawing/revision controls and die/process capability improvement priorities
· 61–90 days: pilot robust design-to-trial-to-SOP handover on selected parts and demonstrate one measurable die/process improvement
Evidence Required During Selection
Ask for 3–5 personally led projects, with baseline, individual contribution, technical decisions, measured outcome and sustained results. Validate claims through a practical BAFPL case and professional references. Assess how the candidate handles disagreement, incomplete evidence and cross-functional ownership.
Governance Principle
Functional owners remain accountable for the quality of the output they create. Quality independently assures customer requirements, stage-gate evidence, process compliance and customer protection. Critical risks and exceptions require documented management decisions; no silent transfer of open risks to mass production.
Please send your resume to contact@kadkraft.com

Work arrangement
No