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Rockman Industries Hiring Assistant Manager – NPD (GDC/Machining) at Cheyyar, Tamil Nadu

Rockman Industries Ltd, a leading manufacturer of aluminium die-cast components for the automotive industry, has announced an exciting and urgent opening for the position of Assistant Manager – NPD (New Product Development). This role is specifically targeted at experienced professionals from the Aluminium Gravity Die Casting (GDC) and Machining domain.

Located in the rapidly growing industrial hub Cheyyar SIPCOT (Tamil Nadu), the position offers excellent exposure to world-class manufacturing systems, customer interactions, APQP/PPAP processes, machining development and complete NPD lifecycle management. If you have hands-on experience in GDC, NPD, tooling development, machining processes, and cross-functional coordination, this is the right opportunity for you.

About Rockman Industries

Rockman Industries is part of the Hero Group and is one of India’s leading manufacturers of aluminium die casting, machining, and composite components for major automotive OEMs. With state-of-the-art manufacturing facilities, automation-driven processes, and strong product engineering capabilities, Rockman serves global customers with high precision, reliability, and on-time delivery.

Working at Rockman offers long-term career stability, exposure to advanced casting technologies, and the opportunity to lead high-impact NPD projects from concept to SOP.

Position Overview

Position: Assistant Manager – NPD (GDC/Machining)
Company: Rockman Industries Ltd
Location: Cheyyar SIPCOT, Tamil Nadu
Industry: Aluminium Gravity Die Casting & Machining (Auto Components)
Experience Required: 6–8 Years
Qualification: Diploma / B.E / B.Tech – Mechanical or related fields
Preferred: Immediate Joiners

This role is ideal for professionals who have previously handled NPD activities in aluminium GDC components, jig/fixture development, machining process development, and customer communication.

Key Responsibilities of Assistant Manager – NPD (GDC & Machining)

1. New Product Development Execution

• Lead complete NPD cycle beginning from RFQ stage to PPAP submission.
• Conduct feasibility study of drawings, customer specifications, and GD&T.
• Develop process flow, layout planning, jig/fixture requirements, tooling design coordination and casting simulation reviews.

2. Gravity Die Casting Development

• Review GDC tool design and gating systems with tool suppliers.
• Conduct mold trials and validate casting parameters.
• Solve casting defects such as porosity, blowholes, shrinkage, misrun, cold shut, etc.
• Ensure casting quality meets metallurgical properties, machining allowances, and dimensional requirements.

3. Machining Development

• Prepare machining process sheets, cycle time calculations, tooling requirements, and cutting parameter selection.
• Coordinate CNC/VMC programming, fixtures development, poka-yoke integration and process validation.
• Achieve target Cp/Cpk for critical features.

4. APQP, PPAP & Documentation

• Prepare control plans, PFMEA, DFMEA inputs, MSA, SPC and SOP documentation.
• Ensure timely sampling and submission of PPAP to customers.
• Maintain complete NPD documentation audit-ready.

5. Customer & Cross-Functional Coordination

• Interact with OEM customers for reviews, feedback, timelines and approvals.
• Coordinate with Design, Tool Room, Casting, Machining, Quality and Suppliers for smooth project execution.
• Handle customer visits, audits, and product demonstrations.

6. Project Management

• Monitor timelines, costs, resource planning, and supplier performance.
• Generate and share weekly MIS reports on project status.
• Ensure adherence to project milestones and SOP readiness.

7. Team Leadership & Problem Solving

• Guide junior engineers and cross-functional team members.
• Use structured problem-solving tools such as 8D, DMAIC, DOE, Fishbone, and 5 Why.
• Improve casting and machining processes through continuous improvement.

Eligibility Criteria

• 6–8 years experience in Aluminium Gravity Die Casting & Machining NPD.
• Strong understanding of tooling, casting parameters, machining programming, fixture design, and APQP.
• Ability to lead cross-functional teams and manage customer communication.
• Proficiency in English, Hindi, and Tamil is mandatory.
• Immediate joiners are highly preferred.

Why Join Rockman Industries?

• Opportunity to work with a global automotive supplier.
• Exposure to advanced GDC and machining technologies.
• Leadership role in major customer development projects.
• Stable and growth-oriented work culture.
• Fast-track career development for high performers.

How to Apply

Interested and qualified candidates can share their updated resumes at:

📩 santhosh.b@rockman.in

Early applicants and immediate joiners will be given preference.

10 Interview Questions & Answers for Assistant Manager – NPD (GDC/Machining)

1. What are the key stages of the NPD process in GDC?

Answer:
RFQ → Feasibility Study → Tool Design → Casting Simulation → Tool Manufacturing → Trials → Machining Development → APQP → PPAP → SOP.

2. How do you conduct a feasibility study for a new aluminium GDC component?

Answer:
By reviewing 2D/3D drawings, GD&T, critical features, machining allowances, draft angles, tooling requirements, and potential casting defects.

3. What are common defects in GDC and how do you reduce them?

Answer:
Common defects include porosity, cold shut, shrinkage, blowholes, misrun, and oxide inclusions. Solutions involve optimizing gating system, temperature control, mold coating, venting, and cycle time.

4. What tools do you use for machining process validation?

Answer:
Cp, Cpk analysis, trial run inspection reports, process capability studies, MSA, fixture trials, and cutting tool trials.

5. How do you ensure PPAP readiness?

Answer:
By preparing DFMEA/PFMEA, control plans, MSA, SPC charts, sample submission parts, dimensional reports, and aligning with customer checklists.

6. What factors affect casting solidification?

Answer:
Melt temperature, mold temperature, gating design, cooling rate, alloy composition, and wall thickness.

7. How do you coordinate GDC suppliers during NPD?

Answer:
Through regular reviews, tooling progress tracking, trial scheduling, defect analysis, and supplier capability assessment.

8. Explain your experience with machining fixture development.

Answer:
Discuss fixture design, clamping methods, fool-proofing, datum selection, rigidity improvement, and reducing cycle time.

9. How do you manage multiple NPD projects simultaneously?

Answer:
By using project tracking tools, weekly MIS, critical path monitoring, and prioritizing based on customer deadlines.

10. How do you handle customer feedback or rejections during development?

Answer:
Through structured RCA, 8D approach, design modification (if needed), process change, and clear communication with the customer.