Process Engineer-1

Orion Castings•Grafton, WI

23d

About The Position

Join us in becoming the premier die casting manufacturer and engineering solutions supplier worldwide. This role focuses on High Pressure Die Casting (HPDC) processes.

Requirements

High-pressure die casting
Die design and tooling
Aluminum/magnesium/zinc casting
Injection systems and shot profiles
Casting defect analysis
DOE and statistical analysis
Root-cause/problem-solving methods
Lean Manufacturing / Six Sigma
SPC, Cp/Cpk, OEE
Familiarity with die-casting machines, furnaces, robotics, and automation

Responsibilities

Develop, optimize, and maintain HPDC processes for quality, productivity, and cost.
Establish and optimize shot profiles, injection speeds, pressures, temperatures, and cooling parameters.
Troubleshoot casting defects including porosity, flash, cold shuts, misruns, soldering, shrinkage, and dimensional variation.
Optimize cycle times, scrap rates, OEE, and material utilization.
Support die design, die trials, and new product launches.
Perform root-cause analysis and corrective actions using structured problem-solving methods.
Develop and maintain process parameters, standards, and work instructions.
Use SPC and process data to monitor and improve process stability.
Work closely with Quality, Tooling, Maintenance, Production, and Controls Engineering.
Support PPAP, capability studies, DOE, and continuous improvement activities.
Ensure processes meet safety, quality, and customer requirements.