Process Engineer - Casting

Magna International Inc. Birmingham , AL 35202

Posted 2 months ago

Job Number: 6639

Group: Cosma International

Division: Kamtek Casting

Job Type: Permanent/Regular

Location: Birmingham

Group Description

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.

Role Summary

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

Key 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 Efficiency.

  • 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.

Key Qualifications/Requirements

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

Additional Information

  • 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
    08--Engineering F--Permanent/Regular

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Process Engineer - Casting

Magna International Inc.