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Process Engineer, Casting

 

Job Introduction

The Process Engineer is responsible for the die cast operations and oversees and leads in their implementation and continuous improvement.

Major Responsibilities

Responsible to support all aspects of Aluminum Die Casting from melting through final machining. Additionally, the Process Engineer will be responsible for new projects, capital improvements, and overall process efficiency.

1)Follow and enforce all plant safety rules and policies.

2)Understand and promote Magna’s philosophies (Magna Operational Principles, Corporate Constitution and Employee’s Charter).

3)Utilize statistical methods (including DOE) to optimize casting process parameters to improve Net Casting Rate.

4)Calculate gate areas using PQ2 methods, runner area and cross-sections to optimize part quality, yield and Net Casting Rate.

5)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 Efficiency.

6)Sample die cast tooling both in plant and at external plants and suppliers.

7)Analyze scrap and determine reason or root cause of problem.

8)Perform cycle time analysis, determine bottleneck operation and implement counter-measures to improve Net Casting Rate

9)Document critical die cast process parameters – make accessible at point of use.

10)Control revision level of process parameters and equipment programs. Responsible to back-up equipment programs.

11)Document all die cast process changes and maintain change history.

12)SME: Furnaces, Die Cast Machine, Die spray system, Die Cast automation

13)Manage equipment suppliers. Manage timing and budget.

14)Review production process to measure compliance to the standard parameters.

15)Promotes good housekeeping (5S)

16)Perform other duties as required.

Knowledge and Education

EDUCATION: High School Diploma or GED required; Bachelor of Science – Mechanical/Industrial Engineering or 5-10 years of related experience in high pressure die castings in the automotive industry

TECHNICAL TRAINING: Die Design, Runner & Cooling Design experience preferred, Catia and 3D CAD experience preferred, Minitab

OTHER: Strong Computer and Microsoft Office Skills (Excel, Word, PowerPoint, Outlook), Lean Manufacturing background & Six Sigma preferred, Knowledge of PLCs, Robotic Programming, Root Cause Analysis, Statistical Problem Solving & DOE

Work Experience

Minimum of 1 year manufacturing, Die Casting Preferred

Skills and Competencies
• Must possess good interpersonal communication skills, including the ability to communicate technical information to a non-technical audience
• Excellent oral and written communication skills
• Team skills
• Ability to work in a fast-paced work environment
• Flexibility to travel in North America and abroad

Work Environment

This position mandates you to wear Personal Protective or Safety Equipment such as Safety Shoes, Glasses, Gloves, Hearing Protection, Hard Hats, & and that all jewelry will be removed while on production/ manufacturing floor. Daily, for short periods of time you could be working around extreme high temperatures (above 900 ° F/ 270C

 

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