Ratnappa Chinchole

Dynamic and results-oriented Assistant Manager with over 18 years of comprehensive experience in the forging industry, specializing in production optimization, new product development (NPD), forging die design, simulation analysis, and quality systems implementation. Demonstrated expertise in designing and developing high-performance forging dies for critical automotive components such as crankshafts, connecting rods, suspension arms, and axle beams. Adept at driving continuous improvement initiatives that enhance yield, reduce costs, and improve product quality.

Proficient in industry-standard tools including AutoCAD, UG (NX CAD), HyperMesh, and Forge Simulation, with a strong command over virtual analysis techniques for material flow, stress distribution, and force prediction. Skilled in interpreting and applying ISO 3469 forging standards, GD&T, and advanced design calculations to ensure manufacturability and performance. Well-versed in quality management systems and tools such as APQP, PPAP, VDA, IATF 16949, PFMEA, and CMMI modules, with a proven ability to lead cross-functional teams, manage vendor coordination, and maintain robust technical documentation.

Recognized for delivering high-impact engineering solutions in ISO 9001 & ISO 14001 certified environments, and for bridging the gap between design intent and production reality through data-driven decision-making and simulation-led validation.

Assistant Manager – Design & Development - BHARAT FORGE LTD. - Mundhwa, Pune

(2014-01)

Expert in the design and development of forging dies for high-performance automotive components such as crankshafts, connecting rods, suspension arms, knuckles, and front axle beams. Demonstrated ability to drive continuous yield improvements by implementing strategic die modifications based on cross-functional brainstorming and production feedback—resulting in cost savings and enhanced component quality for customers. Proactively suggested product design changes to improve mechanical properties and ensure better process compatibility, aligning with both functional and manufacturability requirements.

Integrated advanced simulation tools such as Forge Simulation and HyperMesh to perform in-depth analysis of material flow, stress distribution, and forging forces. These simulations enabled predictive validation of die designs, minimized trial iterations, and ensured defect-free forging outcomes. Backed by strong analytical thinking and hands-on experience, consistently delivered optimized die solutions that balanced performance, cost, and manufacturability—contributing to the overall success of new product development and production efficiency.

• Led the design and development of forging dies for components like crankshafts, connecting rods, suspension arms, knuckles, and axle beams.
• Managed end-to-end NPD lifecycle: concept, process planning, die/tooling design, and validation.
• Created part drawings with GD&T per ISO 3469 standards; performed calculations for area, volume, weight, flash, forces, energy, and yield.
• Conducted stack-up analysis, developed core/tooling drawings, BOMs, and technical documentation.
• Recommended design improvements to enhance mechanical properties and process compatibility.
• Maintained detailed records of design reviews, simulations, and customer feedback.
• Validated forging processes through virtual simulations using Forge Simulation and HyperMesh.
• Analyzed material flow, stress, and filling behavior to ensure defect-free forging.
• Provided simulation insights to support production and NPD decision-making.
• Proficient in VDA, APQP, PPAP, MQP, CMR, IATF 16949, PFMEA, CMMI Modules, and Design Input Check Sheets.
• Ensured lifecycle compliance through structured documentation.
• Supported audits with comprehensive technical records and corrective action reports.

Production Engineer - BHARAT FORGE LTD. - Mundhwa, Pune

(2007-01 - 2014-12)

• Engineered die modifications in collaboration with design and simulation teams, translating production feedback into optimized tooling solutions that improved dimensional accuracy and reduced rework.
• Drove process excellence by leading continuous improvement initiatives on forging lines, achieving measurable gains in productivity, cycle time reduction, and yield enhancement.
• Leveraged simulation tools (Forge Simulation & HyperMesh) to proactively analyze material flow, stress distribution, and forging forces—enabling predictive problem-solving and process validation.
• Orchestrated production planning by aligning manpower, machines, and materials to meet tight delivery schedules while maintaining quality and cost targets.
• Monitored tooling performance and coordinated preventive maintenance to ensure high equipment availability and minimal downtime.
• Championed quality compliance, working closely with QA teams to uphold ISO 9001 & ISO 14001 standards, and actively participated in internal and external audits.
• Maintained comprehensive documentation of process parameters, die performance, and improvement actions to support traceability, audits, and knowledge transfer.
• Mentored and trained shop-floor teams, ensuring adherence to SOPs, safety protocols, and best manufacturing practices for consistent operational excellence.

Master of Technology - Design Engineering - BITS Pillani (2015-01 - 2017-12)