Eng, Manufacturing

Magna International; Telford; On-site; GBP 65,000 - 90,000; Full time

Job summary

Cosma International is seeking a Manufacturing Engineer to own die casting and trim tooling performance, develop data-driven maintenance strategies, and drive continuous improvement. You will lead root-cause investigations and implement engineering changes to reduce scrap and downtime.

The role emphasizes structured problem solving, data analytics using Excel/Power BI, and collaboration with Toolroom and Die-Maintenance teams in a fast-paced manufacturing environment.

Qualifications

• Engineering degree or equivalent experience.
• Experience with structured problem solving (8D, PFMEA, DMAIC).
• Strong statistical data analysis capability (Excel, Power BI, Minitab).
• Hands-on technical experience in manufacturing.
• Familiarity with manufacturing, maintenance, or reliability environments.
• Ability to support live problem solving on the shop floor.

Responsibilities

• Lead engineering ownership of HPDC die and trim tools.
• Analyze tooling performance trends such as flashing, dimensional drift, sticking, thermal imbalance, and surface defects.
• Create and maintain tooling passports covering life, repairs, wear patterns, and capability impacts.

Skills

Structured problem solving

Data analysis

Manufacturing experience

Problem solving leadership

Analytical thinking

Education

Engineering degree

Tools

Excel

Power BI

Minitab

Job description

Role Responsibilities

• Develop dashboards showing die and trim tool performance.

Job descriptions may display in multiple languages based on your language selection.

What We Offer

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.

Group Summary

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.

Job Responsibilities

Position Summary

We are seeking a Manufacturing Engineer with strong capability in developing standard work, data analysis, structured problem‑solving, and Six Sigma methodology.

This role provides end-to-end ownership of die casting and trim Tooling performance, reliability, and lifecycle management. The focus is on preventing recurring issues, improving tooling robustness, and building a data-driven maintenance strategy that reduces scrap, downtime, and variation at source.

While familiarity with tooling and die‑casting processes is beneficial, the primary focus of this role is to analyse tooling‑related performance, identify trends and failure modes, and lead the root cause investigations that drive sustainable improvement.

Role Responsibilities

Die Casting & Trim Tooling Performance Ownership

• Lead engineering ownership of HPDC die and trim tools.
• Analyze tooling performance trends such as flashing, dimensional drift, sticking, thermal imbalance, and surface defects.
• Create and maintain tooling passports covering life, repairs, wear patterns, and capability impacts.

Robust Tooling Maintenance Strategy

• Develop predictive and preventive maintenance strategies for HPDC and trim tooling.
• Define measurable inspection standards for die performance related parameters
• Ensure PMs address real failure modes and verify effectiveness through measurable improvements.

Tooling Data, Analytics & Reporting

• Build automated data collection systems.
• Develop dashboards showing die and trim tool performance.
• Use statistical methods to identify root causes and emerging risks.

Structured Problem Solving & Root Cause Elimination

• Lead 8D, DMAIC, PFMEA and 5-Why activities for tooling failures.
• Ensure corrective actions are embedded in tooling standards and maintenance routines.
• Eliminate recurring tooling defects through engineering changes.

Tooling & Process Support

• Provide engineering support for tooling‑related issues using a data‑first approach, escalating to internal or external tooling experts when required.
• Lead and support tooling‑focused Continuous Improvement (CI) initiatives to improve die life, reduce tooling‑related scrap, and enhance process capability.
• Work with Toolroom and Die‑Maintenance teams to validate improvements and ensure that data insights translate into practical, shop‑floor action.
• Support optimisation of die‑casting tooling (cooling, gating, venting, thermal balance, ejection, cutting clearances, scrap fall) through data‑based analysis.
• Participate in trials, repairs, and modifications by capturing performance data and evaluating their effectiveness with statistical methods.
• Manage projects to develop and implement new processes and technologies.

Standards, Systems & Continuous Improvement

• Lead CI projects targeting tool life, casting capability, and scrap reduction.
• Drive Continuous Risk Reduction through high‑quality PFMEAs, Control Plans, Standard Work, and Maintenance Standards, ensuring they are kept up to date.
• Embed 6σ thinking and statistical discipline across tool maintenance activities.
• Support the development of visual tooling management, 5S, Poka‑Yoke, and standardisation projects within the Toolroom.

The above is an outline of the duties to be performed, and the incumbent will be expected to follow any job‑related instructions and to perform any other job‑related duties as requested by their supervisor.

Essential Experience

• Engineering degree or equivalent experience.
• Experience with structured problem solving (8D, PFMEA, DMAIC).
• Strong statistical data analysis capability (Excel, Power BI, Minitab)
• Hands‑on technical experience in manufacturing
• Familiarity with manufacturing, maintenance, or reliability environments.
• Ability to support live problem solving on the shop floor

Desirable Experience

• Experience in die‑casting, injection molding, or mold/die/tooling environments.
• Experience in implementing new data streams and KPIs
• Predictive maintenance or reliability engineering experience.
• Six Sigma Green Belt or higher.
• CAD/GD&T familiarity.
• Strong knowledge of PFMEA, Control Plans, and APQP documentation.

Personal Attributes

• Data‑driven mindset with strong analytical thinking.
• Hands‑on, proactive approach to solving tooling issues.
• Able to translate complex data into simple, actionable insights.
• Confident leading cross‑functional investigations and challenging assumptions.
• Tenacious, curious, and comfortable working in a dynamic production environment.
• Excellent communication and presentation skills.
• Comfortable in fast‑paced HPDC environments.
• Eligibility to work in the UK.

Work Environment

Plant conditions necessitate exposure to heat, cold, dust, hot objects, and loud noises within our manufacturing environment. Full Health and Safety training and PPE provided for all conditions.

Awareness, Unity, Empowerment

At Magna, we believe that a diverse workforce is critical to our success. That’s why we are proud to be an equal opportunity employer. We hire on the basis of experience and qualifications, and in consideration of job requirements, regardless of, in particular, color, ancestry, religion, gender, origin, sexual orientation, age, citizenship, marital status, disability or gender identity. Magna takes the privacy of your personal information seriously. We discourage you from sending applications via email or traditional mail to comply with GDPR requirements and your local Data Privacy Law.

AI-Assisted Screening Disclosure

As part of our commitment to a fair, consistent, and efficient recruitment process, we may use artificial intelligence (AI) tools to assist in the initial screening of applications submitted through our Workday system. These tools help identify qualifications and experience that align with the role requirements. Please note that AI is used solely to support our recruiters. Final decisions are always made by the hiring manager and the hiring team. Importantly, no applicant data is shared externally through these AI tools. All information remains securely within our systems and is handled in accordance with our privacy and data protection policies.

Under conditions defined by applicable law, you may have the right to request an explanation of how AI is used to support decision-making.

If you have any questions or concerns about this process, feel free to contact our Talent Attraction team.

Worker Type

Regular / Permanent

Group

Cosma International