MGR (ENGG - P&F)

Ather, India

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Job Title

Welding Process planning & development – Automotive Welded assemblies

Reporting

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

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

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: -

Robotic MIG/MAG welding
Resistance spot/seam (circumferential / mash), projection welding
Laser Welding (Continuous/Pulse)
TIG Welding (filler/non-filler)
Gas Brazing / Induction Brazing / MIG Brazing)
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.

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)

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