Purpose of the Role :

This role is responsible to manage new part development with suppliers to facilitate launch of new product or meet the various changes needed in existing products.

Job Responsibilities :

1. Design Feasibility & Supplier Selection Process: Analyse the part design received from Engineering for manufacturability of the part as Matched Pair team along with Engineering and Purchase. Engage with supplier in early vehicle development phase to ensure quality and timely delivery of new parts (EVI - Early Vendor Involvement). Identify, and recommend potential suppliers after receiving SOR from engineering. Shortlist suppliers based on technical capabilities in the sourcing council by conducting technical review sign off (TRSO) along with Purchase, Engineering and FMQ.

2. Part development planning: Prepare a plan for every part (PFEP) under the vehicle build plan. Prepare Advanced part quality plan (APQP) for every part to meet the timelines of vehicle build plan in partnership with supplier. Study the part design and list CTQ parameters to ensure fitment and reliability of the part. Design Validation plan sign off mentioning test start/ end date as per Engineering agreed specifications. Prepare part Manufacturing Planning at supplier end by creating Process Flow Diagram, Floor Plan Layout, PFMEA and RPN Reduction Plan, Facilities Preparation, Machinery & Equipment requirement, Tooling and Packaging Specifications. Verify Tier 2 supplier Planning by validating their Tooling, Equipment, Production capacity, PPAP, Run @ Rate verification. Prepare Quality Plans which includes APQP Program Review frequency, Control Plans, Gauges / Checking Fixtures, Operator and Gauge Instructions, Boundary Samples and TGR/TGW. Plan and verify that the team leaders, quality team members and operators are trained for production and quality of the part. Review in detail and assess readiness for Tooling Kick Off (TKO), Monitor tool development including risks associated.

3. Part Development Process: Obtain initial samples and take quality approval for the part from Quality Assurance team (IR/MR). Conduct 3 stage PPAP by Process Validation, Material Evaluation, Early Production Containment, 1st parts off serial tool, Matching / Dimensional validation, Capability Studies, Run @ Rate. Drive Installation Quality Audit (IQA) along with production quality and supplier for proprietary and black box items. Conduct Vehicle level FTR (Fitment trial report) sign off with required CFT members. Sign off part submission warrant (PSW) to certify that the part has been developed as per required specifications and to meet the planned volume needs. Plan for Early production issue containment to ensure quality of early deliveries. Monitor and prepare PPM report of the developed part for a fixed duration.

4. Tool management and Cost Reduction: Identify VAVE opportunities and implement to achieve cost reduction targets. Manage tool capitalisation and process pay outs. Conduct the tool audits, get the identified issues closed and submit audit/closure reports.

5. Supplier Management Process: Conduct MSA to determine supplier health and identify improvement areas. Prepare an optimised strategic supplier base to meet the organisational requirements. Resolve CCT issues. Plan for demand fluctuations, create capacities as needed and monitor part supplies to meet volume forecast.

6. Relationship Management: Develop and maintain good relationships with the stakeholders for smooth processes and achieve optimal quality performance.

7. People Management: Identify areas of technical improvement, plan training interventions and train the suppliers.

Stakeholder Profiles & Nature of Interactions: Internal:

Purchasing

TRSO process, Fixture/Tooling /Gauge PO release, Tooling payment.

Head SQ Admin & Functional Reporting. Report status on project wise developments

Product Line Review of project timelines, information/clarification on vehicle build plan(alpha/beta/sop)

SCM Details of newly developed parts and part handover for scheduling

Manufacturing ECN change related details, quality/supply matters of development parts

Engineering Drawings & SOR, Green report approval, Engineering change approval if any, Tool kick off go ahead External: Suppliers Drawings, SOR & development related process communication

Required Skills:

Strong knowledge of Seating & Interior Trim manufacturing processes.

Experience in APQP, PPAP, FMEA, MSA, SPC, Control Plans, and GD&T.

Hands-on experience in supplier audits and quality problem-solving.

Knowledge of plastic molding, foam molding, upholstery, and trim assembly processes.

Exposure to automotive quality standards (IATF 16949, VDA, AIAG).

Strong analytical and stakeholder management skills.

Preferred Background :

BE/B.Tech in Mechanical, Production, Automobile, or Industrial Engineering.

Experience with Automotive OEMs or Tier-1 suppliers.

Familiarity with Seating Systems commodities.

Senior Manager - SQ Trims

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