Process Engineer - Die Cast

aisincareers; Clinton (TN); On-site; USD 70,000 - 100,000; Full time

Job summary

Aisin Automotive Casting Tennessee Inc. is seeking a Process Engineer in Clinton, TN, to enhance aluminum die casting processes and drive quality, yield, and efficiency improvements. You will work with cross-functional teams to implement new technologies and sustain manufacturing excellence.

The role emphasizes process design, problem solving, and data-driven improvements, with a focus on traceability, automation, and safe, compliant operations on site.

Qualifications

• Bachelor’s degree or 4–6 years related experience, or equivalent combination of education and experience.
• 3+ years in aluminum die casting or metal casting manufacturing engineering.
• Experience with laser marking, 2D matrix codes, and traceability processes.

Responsibilities

• Develop, optimize, and troubleshoot aluminum die casting processes to improve quality, yield, and cycle time.
• Collaborate with toolmakers and maintenance teams to ensure dies, tooling, and equipment meet production requirements.
• Oversee laser marking operations and ensure accurate, traceable markings across production.
• Lead root cause analysis for quality issues and process failures to implement corrective actions.
• Maintain process documentation, SOPs, and performance reports; drive improvements in cost, energy use, and waste reduction.
• Work with cross-functional teams to align maintenance and manufacturing objectives.

Skills

Aluminum die casting processes

Root cause analysis

Lean manufacturing knowledge

Problem-solving skills

Communication skills

Team collaboration

Cross-functional teamwork

Manufacturing process optimization

Education

Bachelor’s degree or 4–6 years related experience

Tools

CAD software (SolidWorks, AutoCAD)

Fanuc robotics

Laser marking systems

2D matrix codes

Casting simulation tools

Job description

Job Title: Process Engineer

Company: Aisin Automotive Casting Tennessee Inc.

Department: Die Cast

Location: Clinton, TN

Position Summary

As a Die Casting Manufacturing Engineer at Aisin Automotive Casting Tennessee, you will be responsible for improving, optimizing, and sustaining aluminum die casting manufacturing processes to meet high-quality standards and production efficiency. You will collaborate with cross-functional teams to solve engineering challenges, introduce new technologies, and contribute to the overall success of our operations.

Position Responsibilities

• Process Optimization:Develop, optimize, and troubleshoot aluminum die casting processes to improve product quality, yield, and cycle time.
• Tooling and Equipment Maintenance:Collaborate with toolmakers and maintenance teams to ensure that dies, tooling, and equipment are properly maintained and meet production requirements.
• Laser Marking:Oversee and optimize the laser marking of parts, including the implementation of 2D matrix codes for traceability and quality assurance. Ensure accurate and consistent marking throughout the production process.
• Auto Deburring:Manage and improve the auto deburring process, ensuring that parts are free of burrs, sharp edges, and other imperfections to meet required quality standards.
• Trim Pressing:Oversee trim pressing operations to remove excess material, ensuring the final product meets design specifications while maintaining process efficiency.
• Distortion Tables:Utilize distortion tables to monitor and correct any material distortion or warping during the die casting process, ensuring product quality and dimensional accuracy.
• Quality Control:Ensure that aluminum die-cast parts meet engineering specifications, quality standards, and customer requirements by applying effective measurement and testing techniques.
• Process Design & Improvement:Recommend and implement improvements to existing processes, equipment, and layouts, focusing on cost reduction, energy efficiency, and waste minimization.
• Root Cause Analysis:Lead root cause analysis for quality issues, process failures, and non-conformities to implement corrective actions and prevent recurrence.
• Documentation and Reporting:Maintain detailed records of process changes, trials, and troubleshooting activities. Generate process documentation, standard operating procedures (SOPs), and other technical reports.
• Collaboration:Work closely with cross-functional teams, including production, quality assurance, and R&D, to ensure alignment between maintenance and manufacturing.

Qualifications:

• Education:Bachelor’s degree from an accredited college or university or 4 to 6 years of related experience and a HS Diploma or G.E.D., or equivalent combination of education and experience.
• Experience:3+ years of experience in aluminum die casting or metal casting manufacturing engineering.
• Skills:
  • In-depth knowledge of aluminum die casting processes.
  • Experience with laser marking, 2D matrix codes, and traceability processes.
  • Proficiency in CAD software (e.g., SolidWorks, AutoCAD) and familiarity with simulation tools for casting processes.
  • Strong understanding of metallurgy, tooling design, and production methodologies.
  • Experience with auto deburring, trim pressing, and distortion table operations is highly desirable.
  • Fanuc robotics experience for automation and robotic systems integration in manufacturing processes.
  • Experience with lean manufacturing, Six Sigma, or similar continuous improvement methodologies is a plus.
  • Excellent problem-solving skills and a strong focus on root cause analysis.
  • Strong communication skills, both written and verbal, with the ability to work in a collaborative team environment.
• Certifications:Lean Six Sigma certification or equivalent is a plus.

Travel Requirements

• Approximately 0 %
• Must be willing and available to travel to such locations and with such frequency as is necessary and desirable to meet business needs.

Work Environment Requirements

With reasonable accommodation:

• Must be able to operate a personal computer, telephone, and other office equipment.
• Must perform job duties onsite, when necessary, except those duties that are customarily or by their nature performed offsite (for example, offsite customer visits).
• Must be able to work effectively in a fast-paced environment.
• Must be able to work on multiple assignments at once, and complete assignments within deadline and budget (if applicable) with satisfactory quality.
• Must be able to operate as an effective team member.
• Must be committed to a high standard of safety and be willing and able to comply with all safety laws and all company safety policies.

Attendance/Work Hour Requirements

• Must maintain an acceptable attendance record.
• Must be willing and available to work weekends and holidays as necessary and desirable to meet business needs.