Tooling Engineer - Casting

Magna International•Birmingham, AL

10d•Onsite

About The Position

At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are. Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Requirements

5-10 years related experience in the high pressure die castings in the automotive industry
Die Design, Runner & Cooling Design experience
Proficient in 2D and 3D CAD
BS - Mechanical/Industrial Engineering
Knowledge of Root Cause Analysis
Good interpersonal skills
Excellent oral and written communication skills
Ability to work in a fast paced working environment
Fundamental computer skills using Microsoft Office suite, MS Project and Minitab
Must be able to understand written instructions

Nice To Haves

Lean Manufacturing background & Six Sigma preferred

Responsibilities

Manage the cast and trim tooling used for production and prototypes.
Promote and practice “safety first” by immediately addressing any hazards, defective equipment, or unsafe conditions within the department.
Manage die cast die and trim tooling build, design and spare parts to produce the highest Net Casting Rate.
Design die cast dies: runner, cooling, vacuum systems, etc. to ensure best part quality and optimize yield.
Design die seals for best vacuum performance and leak prevention.
Calculate and design cooling system to ensure best part quality and optimal cycle time.
Optimize tooling performance by utilizing coatings and materials to improve die life and reduce/eliminate soldering.
Design features that facilitate quick die change.
Maintain list of standard tooling components (cylinders, limit switches, prox switches, etc.).
Develop and maintain die standards to: 1. Improve production performance (net casting rate), 2. Optimize casting yield and, 3. Minimize tooling costs / good casting.
Collaborate with Tool Room Manager to develop and maintain Tooling PM System.
Responsible for improving uptime and reducing maintenance costs of DC & Trim dies. Determine root-cause analysis and implement counter-measures.
Analyze die IR images and improve die cooling to improve thermal balance of DC die.
Utilize 3D FEA, Flow and Solidification analysis to improve designs.
Perform dimensional analysis, implement counter-measures to improve dimensional capability. Complete understanding of casting tolerances and GD&T.
Collaborate with Machining Engineer to minimize machining stock and machining operations.
Oversee tooling builds with tool shops. Manage timing and budget.
Maintain master tool drawings. Provide access to Tool Room staff for all tooling maintenance – minimizing downtime and costs.
Optimize shot component life (shot component cost/good shot).
Calculate tooling clearances based on thermal expansion and minimum flow distances.
Utilize poke yokes in tool design to prevent mis assembly.
Perform other duties as required.