Mgr (Engg - P&F)

Division

Department

Engineering

Level / Grade

L3

Functional Area

Welding Technology

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Job Title

Welding Process planning & development – Automotive Welded assemblies

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Reporting

Functional reporting to:  GM (Engg. _ P&F _ Welding Technology)

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Background

i) Educational Qualification

Desirable: B.E. Mech / M. Tech (Welding Technology) _ Preferred

ii) Experience

Minimum:  3

Maximum: 10

iii) Age Limit

Minimum:  25

Maximum: 35

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Job Role & Responsibilities

Role: Planning and Development of Innovative Joining Technologies e.g. Welding, Soldering, Brazing etc. for 2Wh EV components (e.g. Battery, Motor etc) & 2Wh / 3Wh IC components (e.g. Fuel tank, Frame body, silencer & CV (commercial vehicle) weldments

Responsibilities:

New Process Development

• Explore development and productionization of innovative welding technologies


• Adoption of emerging welding technologies (e.g. SM laser with core + ring beams & LDD; EBW, FSW etc.)


• AI adoption (data annotation), analysis, digital twin) – smart manufacturing

Process Planning

• Design simplification & rationalization of new model parts & identifying DFM/A, PQS-CTQ points.


• Process planning for standard process & process parameters optimization.  

Flawless Manufacturing & Product quality enhancement

• Resolution of QSR / Field Quality issues and IHR Quality issues at Vendor


• Improve Process reliability for zero defect supplies


• Aesthetics improvement of weldments.

New Product Development

• Selection of Joining process wrt joint design for new products to achieve zero defect, lowest cost & timely delivery


• To establish necessary Poka-Yoke/interlocks for fool proof manufacturing of weldments.


• Design and development of welding fixtures

Cost reduction & Capital Investment avoidance

• To generate VAVEs for welding parts cost reduction


• Right sizing of equipment for investment cost reduction

Green processes

• Adoption of Green processes in welding


• Resource conservation in welding processes.

Competency Requirements

Technical/ Functional:

• Extensive work exposure in EV components required, e.g. Cell terminals welding in EV battery, copper terminals welding in motor, wave soldering & Surface mounted technology (SMT) for making PCBs, and thorough knowledge of innovative welding technologies like Continuous/Pulse/SM Laser Welding, Parallel Electrode Transistor based Series spot/projection welding, ultrasonic wire bonding etc.


• Work exposure and thorough knowledge about dissimilar material joining (e.g. copper to steel, Aluminum to steel etc.), thin sheet with unequal thicknesses joining (e.g. min. 0.2 mm to max. 3 mm)


• Thorough knowledge of following conventional welding processes: -

1. Robotic MIG/MAG welding


2. Resistance spot/seam (circumferential / mash), projection welding


3. Laser Welding (Continuous/Pulse)


4. TIG Welding (filler/non-filler)


5. Gas Brazing / Induction Brazing / MIG Brazing)


6. Soldering (Wave soldering, SMT etc.)

• Expertise in understanding welding simulation software’s (e.g. Simufact, Sysweld etc.)


• Knowledge of welding metallurgy


• Knowledge of Welding fixture concepts


• Knowledge of welding quality inspection techniques - NDT/DT


• Expertise in setting up optimum weld process parameters.


• Capability to analyze & resolve defects reported.


• Thorough knowledge about process/ fixtures tryout & proving procedures.


• Knowledge about automotive industry standards and regulations applicable.

Soft Skill set:

• Excel, Power Point, SAP, Team Centre, NX Unigraphics, Welding                Simulation analysis software’s

Behavioral

• Effective communication with team, vendors & management


• Candidate should be able to work in a dynamic and challenging environment to meet deliveries as per schedule.


• Good Interdepartmental co-ordination skills.

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Likely sources

Organization example-

• EV Battery welding manufacturing industries (e.g. Ather, TACO, Ola, BOSCH, Hero Vida, TVS etc.)


• Laser Welding machine manufacturers (e.g. IPG, Trumpf, Amada, Panasonic)