Senior Process Engineer - Casting

General Motors•Warren, MI

3d•Onsite

About The Position

The Launch Process Engineering Team excels in the development, testing, implementation and execution of new casting programs, platforms and technology. This group is unique in that by working with and across multiple levels of the GM technical groups, vendors and suppliers, the complex problems of casting projects are developed into controlled manufacturing processes. The Specific Purpose of this position is to perform casting manufacturing projects by following a systematic engineering process of evaluation, development, validations, technology transfer leading into and supporting the production launch and processing. Specifically responsible and directly involved in the development of manufacturing processes, equipment, tooling and alternatives, sequences, operations, utilizations for the production of castings.

Requirements

3+ years of professional experience in a manufacturing environment
Demonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environment
2+ years of professional experience in Low Pressure Die Casting, Precision Sand, Semi Permanent Mold or similar, tooling, process, quality, or project management experience.
Knowledge of process engineering procedures and disciplines
Basic knowledge of Magma, Flow 3D, simulation software
Basic knowledge of NX or Catia or any 3D design software
Effective and functional knowledge of aluminum chemistry, heat treat, metallurgical processes
Demonstrated understanding of mechanical concepts involving machine design, process equipment, tooling, and secondary post processing
BS degree (engineering, metallurgical, computer science) or equivalent experience is required

Nice To Haves

Training in aluminum metallurgy
Prior experience in Low Pressure Die Casting, Precision Sand or Semi Permanent Mold
Prior experience in injection molds
Prior experience in castings or Giga/Structural castings
Training in flow simulations ( Magma, Flow 3d)
Training in 3D design software
Mechanical properties testing and procedures
Background in Aluminum chemistry is encouraged
Training in Problem solving

Responsibilities

Ability to work individually on specific programs yet collaboratively with Launch Team, QC, Design, Tooling, and other support groups
Demonstrate technical knowledge of foundry processes and ability to apply concepts in a manufacturing environment
Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
Support testing and installations of equipment, tooling and technologies both on and off site
Lead, support and present the analysis of casting defects
Assist in process, tooling and equipment testing, troubleshooting and implementations
Develop process documentation, Process flow diagrams, PCP, PFMEA, TIS, and related technical documents as necessary for a program launch
Analyze first time quality data and optimize processes using DOE, Red X, and related statistical tools
Perform both Non and destructive testing procedures for casting investigation and analysis (leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc)
On site work, working on shop floor, hands on equipment, understanding of casting shop activity.