Process Engineer - Casting

Job Number: 69661
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.
PURPOSE OF POSITION
The Process Engineer is responsible for the die cast operations and oversees and leads in their implementation and continuous improvement.
RESPONSIBILITY AND AUTHORITY
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.
ESSENTIAL FUNCTIONS OF THE POSITION:
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.
POSITION REQUIREMENTS
SKILL (Ability to do the job):
• 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
OTHER KNOWLEDGE/WORK EXPERIENCE
PHYSICAL DEMANDS:
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).
EQUIPMENT/TOOLS USED:
Some of the equipment and tools used are a computer, telephone, fax machine, copier/printer and tools required in Die Casting.
EDUCATION: High School Diploma or GED required; Bachelor of Science - Mechanical/Industrial Engineering or 5-10 years of related experience in high pressure die casting 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: WHAT TYPERS? Manufacturing, Die Casting Preferred HOW MUCH? Minimum of 1 year
WHAT ADDITIONAL SKILLS OT ABILITIES WOULD BE HELPFUL FOR THE JOB? Knowledge of the automotive manufacturing industry
08--Engineering F--Permanent/Regular