Process Engineer - Casting

Magna-International-6df39721; Birmingham (AL); On-site; USD 60,000 - 78,000; Full time

Job summary

Magna International, Cosma division, seeks a Process Engineer to lead die cast operations, implement improvements, and drive Net Casting Rate through DOE and process optimization. The role requires collaboration with tooling, supplier management, and cross-functional teams in a fast-paced manufacturing setting.

Applicants should have 5–10 years in high pressure die casting for automotive, strong Lean/Six Sigma knowledge, and hands-on experience with PLC/robot programming.

Qualifications

• BS in Mechanical or Industrial Engineering.
• 5–10 years in high pressure die casting in automotive.
• Lean manufacturing background; Six Sigma preferred.
• Strong problem solving and written/oral communication.

Responsibilities

• Utilize DOE to optimize casting process parameters.
• Calculate gate areas and runner/cooling system impacts.
• Collaborate on runner and cooling system design with tooling engineer.
• Evaluate simulation results and implement counter-measures.
• Analyze scrap, perform cycle time analysis, and identify bottlenecks.
• Document process changes and maintain change history.
• Manage equipment suppliers and project timing/budget.
• Travel to Ontario and abroad as needed.

Skills

Statistical problem solving

DOE (design of experiments)

Root cause analysis

PLC knowledge

Robot programming

Lean manufacturing

Six Sigma

AutoCAD

Minitab

MS Office / MS Project

Education

BS - Mechanical/Industrial Engineering

Tools

AutoCAD

Minitab

PLC

Robot programming

Job description

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:Job SummaryThe Process Engineer is responsible for the die cast operations and oversees and leads in their implementation and continuous improvement.The requirements listed below are representative of the knowledge, skill, ability and essential duties required to successfully perform this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.Essential Duties and ResponsibilitiesUtilize statistical methods (including DOE) to optimize casting process parameters to improve Net Casting RateCalculate gate areas using PQ2 methods, runner area and cross-sections to optimize part quality, yield and Net Casting RateCollaborate 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 RateSample die cast tooling both in plant and at external plants and suppliersAnalyze scrap and determine reason or root cause of problemPerform cycle time analysis, determine bottleneck operation and implement counter-measures to improve Net Casting RateDocument critical die cast process parameters – make accessible at point of useControl revision level of process parameters and equipment programs. Responsible to back-up equipment programsDocument all die cast process changes and maintain change historySME: Furnaces, Die Cast Machine, Die spray system, Die Cast automationManage equipment suppliers. Manage timing and budgetReview production process to measure compliance to the standard parametersQualifications5-10 years related experience in the high pressure die castings in the automotive industryRunner & Cooling Design experienceBS - Mechanical/Industrial EngineeringKnowledge of PLC, Robot programming, Root Cause Analysis, Statistical Problem Solving & DOELean Manufacturing background & Six Sigma preferredGood interpersonal skills and “hands-on” problem solving expertiseExcellent oral and written communication skillsAbility to work in a fast paced working environmentFlexibility to travel in Ontario and abroadFundamental computer skills using Microsoft Office suite, MS Project, AutoCAD and MinitabMust be able to understand written instructionsWork EnvironmentIncludes office and manufacturing plantMust be able to perform all essential functions as appropriate on the plant floor, in meetings, and with employees of all departments, management, customers and suppliersProvide support for three shifts and weekend production schedule as required by managementFlexible hours and able to work additional hours as requiredWork AuthorizationApplicants must be legally authorized to work in the United States at the time of hire. Candidates who currently hold valid work authorization under a TN or H-1B visa may be considered, provided they are authorized to work for this employer without requiring new or additional visa sponsorship. The company is unable to sponsor new employment-based visas or other immigration sponsorship for this position.Other ConsiderationsThis job description in no way states or implies that these are the only duties to be performed by the employee occupying this position. Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their manager.A review of this description has excluded the marginal functions of the position that are incidental to the performance of fundamental job duties. All duties and requirements are essential job functions.Requirements are representative of minimum levels of knowledge, skills and/or abilities. To perform this job successfully, the incumbent will possess the abilities or aptitudes to perform each duty proficiently.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 DisclosureAs 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 / PermanentGroup:Cosma International