Process Engineer - Casting

Magna International•Birmingham, AL

1d•Onsite

About The Position

The Process Engineer is responsible for the die cast operations and oversees and leads in their implementation and continuous improvement. The requirements listed below are representative of the knowledge, skill, ability and essential duties required to successfully perform this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Requirements

5-10 years related experience in the high pressure die castings in the automotive industry
Runner & Cooling Design experience
BS - Mechanical/Industrial Engineering
Knowledge of PLC, Robot programming, Root Cause Analysis, Statistical Problem Solving & DOE
Good interpersonal skills and “hands-on” problem solving expertise
Excellent oral and written communication skills
Ability to work in a fast paced working environment
Flexibility to travel in Ontario and abroad
Fundamental computer skills using Microsoft Office suite, MS Project, AutoCAD and Minitab
Must be able to understand written instructions

Nice To Haves

Lean Manufacturing background & Six Sigma preferred

Responsibilities

Utilize statistical methods (including DOE) to optimize casting process parameters to improve Net Casting Rate
Calculate gate areas using PQ2 methods, runner area and cross-sections to optimize part quality, yield and Net Casting Rate
Collaborate with Tooling Engineer with the design of the runner and cooling system. Evaluate simulation results and casting trial results, implement counter-measures to optimize Net Casting Rate
Sample die cast tooling both in plant and at external plants and suppliers
Analyze scrap and determine reason or root cause of problem
Perform cycle time analysis, determine bottleneck operation and implement counter-measures to improve Net Casting Rate
Document critical die cast process parameters – make accessible at point of use
Control revision level of process parameters and equipment programs. Responsible to back-up equipment programs
Document all die cast process changes and maintain change history
SME: Furnaces, Die Cast Machine, Die spray system, Die Cast automation
Manage equipment suppliers. Manage timing and budget
Review production process to measure compliance to the standard parameters