Process Engineer

Dicastal North America Inc.; Livonia (MI); On-site; USD 80,000 - 100,000; Full time

Job summary

A manufacturing company in Livonia, Michigan is seeking a Casting & Manufacturing Process Engineer. The ideal candidate will specialize in aluminum casting simulation and process optimization, focusing on enhancing manufacturability, quality, and efficiency. Responsibilities include advanced casting simulations, leading trials, and ensuring production quality across departments. Strong communication skills in English are essential, with a preference for Mandarin proficiency.

Qualifications

• 5-10 years of experience in process engineering, preferably in automotive.
• Strong proficiency in casting simulation software.
• Experience writing procedures and work instructions.

Responsibilities

• Perform advanced casting simulations using MAGMA or ProCAST.
• Analyze simulation outputs for defect formation.
• Lead casting trials and refine process parameters.

Skills

Aluminum casting simulation

Process development

Machining knowledge

Lean Manufacturing

Technical documentation

Team collaboration

Communication skills in English

Mandarin Chinese (optional)

Education

Bachelor’s or Master’s degree in Mechanical Engineering

Tools

MAGMA

ProCAST

Microsoft Word

Microsoft PowerPoint

Job description

Overview

We are seeking a Casting & Manufacturing Process Engineer with strong expertise in aluminum casting simulation and process development, complemented by knowledge of machining and assembly processes. The primary focus of this role is casting simulation, trial validation, and process optimization, while also supporting downstream machining and assembly operations to ensure seamless product industrialization and drive excellence in manufacturability, quality, and efficiency. The ideal candidate will have deep expertise in hands-on knowledge of Low-Pressure Casting and Counter Pressure Casting technologies.

Responsibilities

• Casting Process (Primary Focus) Perform advanced casting simulations using MAGMA, ProCAST or other software.
• Analyze simulation outputs for mold filling, temperature gradients, solidification behavior, and potential defect formation.
• Lead casting trials to validate simulation results and refine key process parameters for optimal outcomes.
• Direct mold design efforts and establish robust casting process settings to ensure repeatability and quality.
• Develop and implement process standards, best practices, and defect prevention guidelines specific to aluminum casting operations.
• Evaluate machining sequences, fixturing solutions, and dimensional tolerances to ensure compatibility with casting design and processes.
• Collaborate closely with cross-functional manufacturing teams to troubleshoot and resolve quality issues across casting, machining, and assembly stages.
• Prepare detailed technical documentation, including reports and presentations, utilizing Microsoft Word and PowerPoint.
• Communicate findings, insights, and technical recommendations to engineering, tooling, machining, and manufacturing teams.
• Drive continuous improvement initiatives aimed at enhancing yield, reducing defects, and improving cost efficiency.
• Occasional business travel to China and Mexico.

Skills and Experience

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or related field.
• 5–10 years of experience in process engineering (preferably automotive).
• Strong proficiency in MAGMA, ProCAST, or other casting simulation software.
• Working knowledge of Lean Manufacturing principles.
• Knowledge of machining fundamentals and assembly requirements.
• Experience writing procedures and work instructions.
• Well-versed in automotive manufacturing standards, quality systems, and core tools such as APQP and PPAP.
• Working knowledge of word processing and spreadsheet software in use.
• Proven track record in supporting global, cross-cultural engineering projects and diverse team environments.
• Strong written and verbal communication skills in English, with all levels of the company.
• Mandarin Chinese proficiency (written/verbal) is a plus.

Organizational Culture

• Work safely and follow rules and guidelines for safe work.
• Reporting to work on time and with a positive attitude.
• Responsible for staying focused on tasks at hand.
• Being responsible for work performance and completing tasks throughout the day.
• Maintains a good working relationship with co-workers.
• Support a positive and steady workflow through the company.
• Works with a sense of urgency when needed.
• Support, coach or mentor co-workers when needed.
• Positively support change throughout the company.

Physical Work Conditions

• Must be able to work in a hot environment.
• Must be able to lift and move aluminum wheels of varying weight.
• Must be able to lift 50 – 65 pounds.
• Must be able to stand and walk for up to 12 hours per day.
• Must be able to wear personal protective equipment when required.