Process Engineer

Aegis Worldwide; Madison (WI); On-site; USD 75,000 - 110,000; Full time

Job summary

Aegis Worldwide is assisting a client in Wisconsin to fill a Die Casting Engineering role focused on providing engineering and production support for robust die casting manufacturing processes. The position emphasizes improving quality, efficiency, and process stability while aligning with APQP and launch activities.

You will develop tooling concepts, run process simulations, and document procedures to ensure consistent customer requirements are met.

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• Experience in a manufacturing environment.
• Familiarity with ABB robotics and die casting controls preferred.
• Strong problem-solving and analytical abilities.
• Ability to lead cross-functional teams and communicate effectively.
• English proficiency required.

Responsibilities

• Provide engineering and production support for die casting operations.
• Develop and improve robust manufacturing processes.
• Support new product launches per APQP.
• Manage tooling design, process simulation, and documentation.
• Lead process improvement initiatives to increase uptime and reduce scrap.
• Provide training and guidance to production personnel.
• Ensure compliance with quality requirements and safety standards.
• Document PFMEAs, control plans, and process flows.

Skills

Root cause analysis

Cross-functional teamwork

Problem-solving

Process optimization

Documentation and training

Education

Bachelor's degree in Mechanical Engineering

Tools

ABB robotics

Die casting controls

Job description

• Provide engineering and production support for die casting operations by developing, maintaining, and continuously improving robust manufacturing processes.
• Develop cost-effective, high-quality production methods while ensuring customer quality requirements are consistently met or exceeded.
• Support new product launches in accordance with established APQP and launch processes.
• Manage and support assigned die casting processes, including tooling design and support, process simulation, process development, production support, employee training, process documentation, and selection of consumable tooling.
• Lead or support production improvement initiatives focused on increasing equipment uptime, reducing scrap, and improving overall process performance.
• Evaluate the impact of process changes on dimensional accuracy, part quality, and overall process stability, ensuring changes maintain or improve product quality.
• Consider the effects of die casting process changes on downstream operations, including trimming, finishing, machining, and painting.
• Lead or support sampling, troubleshooting, and correction of replacement tooling, including investigation and resolution of dimensional issues.
• Support the development and standardization of manufacturing best practices across multiple production facilities.
• Support launch teams with APQP documentation, including inspection sheets, process flows, PFMEAs, and control plans.
• Monitor and improve process stability to ensure production meets customer requirements for quality, productivity, and performance.
• Provide technical guidance and training to production personnel as needed.
• Perform other related duties and responsibilities as assigned.

Qualifications

• Bachelor's degree in Mechanical Engineering or a related engineering discipline, with experience in a manufacturing environment.
• Equivalent combinations of education and relevant experience may be considered.
• Familiarity with ABB robotics/programming and die casting machine controls is preferred.
• Strong problem-solving and analytical skills with the ability to identify root causes and implement effective corrective actions.
• Demonstrated leadership skills and the ability to work effectively with cross-functional teams.
• Ability to work effectively under pressure and manage multiple priorities in a production environment.
• Proficiency with computers and the ability to learn and utilize new software and manufacturing systems.
• Strong written and verbal communication skills.
• Ability to read, write, and communicate effectively in English.
• Ability to perform the essential functions of the position with or without reasonable accommodation.

Other

• This position operates in a heavy manufacturing environment with exposure to machinery, industrial equipment, manufacturing processes, chemicals, ergonomic hazards, machine points of operation, and powered industrial vehicle traffic.
• Appropriate safety controls, procedures, and personal protective equipment are utilized to minimize workplace hazards.
• The work environment may range from moderate to noisy. Depending on the work area, required personal protective equipment may include hearing protection, safety glasses, safety-toe footwear, and hand protection.
• The position requires regular movement throughout manufacturing areas and may require standing, walking, stooping, bending, reaching, and use of hands to manipulate objects or controls.
• The employee must be able to lift and/or move up to 50 pounds.
• This job description is intended to describe the general nature and level of work performed and is not an exhaustive list of all duties, responsibilities, or activities. Responsibilities may be modified as business needs change.