Process Engineer - Die Cast

AW Technical Center USA; Clinton (TN); On-site; USD 70,000 - 90,000; Full time

Job summary

A manufacturing company in Tennessee is seeking a Die Casting Manufacturing Engineer to improve and optimize aluminum die casting processes. The role involves collaboration with cross-functional teams, ensuring quality standards, and troubleshooting engineering challenges. The ideal candidate has a Bachelor's degree, over 3 years of relevant experience, and skills in CAD software. Lean Six Sigma certification is a plus.

Qualifications

• Bachelor’s degree or equivalent combination of education and experience.
• 3+ years in aluminum die casting or metal casting manufacturing engineering.
• Experience with lean manufacturing or Six Sigma methodologies.

Responsibilities

• Develop, optimize, and troubleshoot aluminum die casting processes.
• Collaborate with teams to oversee tooling and equipment maintenance.
• Implement improvements for cost reduction and waste minimization.

Skills

Laser marking

CAD software proficiency

Metallurgy understanding

Problem-solving

Lean manufacturing experience

Education

Bachelor’s degree or equivalent experience

Tools

SolidWorks

AutoCAD

Job description

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.

Location: Clinton, TN

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: 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.