Casting Manufacturing Engineer

Casting Manufacturing Engineer

Work Location: Dearborn, Michigan

Position Description

In this role, the Casting Manufacturing Engineer will work with Product Development and Suppliers, to successfully develop and launch next-generation castings. Successful candidates will have a proven record of working with cross functional teams in the development and implementation of complex castings.

The Casting Manufacturing Engineer will be required to apply their knowledge to various casting alloys and processes, including but not limited to gravity, low-pressure, and high pressure die casting. Knowledge of various core making processes and materials will be useful. In this role, the casting engineer will have direct impact over the design and processing of castings in future products. Ideal candidates must navigate and drive change in a complex internal environment, challenging the status quo as we define an all-new way of manufacturing vehicles.

Responsibilities

• Drive the casting process and provide a framework to enable the cross functional teams to create Program / Component specific plans, for the development and implementation of manufacturing feasible casting designs and processes resulting in parts that can be machined by standard and best practice methods in support of new program product launches.

These roles include and are limited to the following:

• Provide technical support to Product Development (PD) Component Program Module Teams (CPMT's) and coordinate casting design between Product Engineering, PTME - Machining and external casting suppliers to assure ‘design for manufacturing feasibility’ of new Powertrain castings.
• Support new model program cost studies and projects.
• Support the Digital Preassembly 5 (DPA5) process through the development of component Manufacturing Design Specifications (MDS) and Manufacturing Process Specifications (MPS). Complete Manufacturing Assessments.
• Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering and supplier organizations.
• Support supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of suppliers and subcontractors.
• Provide support for casting prototype planning, process development and scheduling.
• Support on-time quality prototype delivery of new components at internal and external supplier facilities.
• Evaluate innovative and disruptive emerging processes and material technologies for potential application to products.
• Support Product Engineering in the selection and specification of component materials and test procedures.
• Assist manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.
• Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of casting related productivity and quality issues and the development of external casting suppliers.

Qualifications

Minimum Requirements

• Bachelor of Science/Engineering; MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science.
• 5 years prior experience with high pressure die casting, low pressure die casting, gravity die casting, or sand casting.
• Strong communication skills, both written and oral.
• Working level knowledge of casting, post processing, and die development processes.
• Working level knowledge of core making processes and materials.
• Knowledge of the secondary operations associated with castings, including, but not limited to trimming, fettling, deburring, and quality checks.
• Knowledge of both iron and aluminum alloys used for castings.
• Understanding of MagmaSoft or other casting simulation software results.
• Excellent problem-solving skills and the ability to make decisions in a fast paced, dynamic environment.
• Exceptional communication and interpersonal skills to present, persuade, and collaborate at all levels of the organization.
• Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority.
• Experience performing casting manufacturing feasibility assessments.
• Foundry operational experience in casting manufacturing processes and process control.
• Proven track record of delivering major product launches in an automotive manufacturing facility.
• Ability to work in a production setting and aid in troubleshooting of supplier equipment and processes. Possess practical problem-solving skill and the ability to address a variety of variables in situations where only limited standardization exists.
• Ability to travel both domestically and internationally.