Process Engineer - Casting

Cosma International Birmingham, AL

About the Job

##### Company Introduction Kamtek is a Tier 1, automotive manufacturing supplier that specializes in Metal Stamping and Assembly for Mercedes, Volkswagon, Kia and Hyundai. As a local distributor and supplier, Kamtek’s market segmentation to Cosma International, (a division of MAGNA INTERNATIONAL) provides a “state-of-the-art” product that utilizes the most technologically advanced Pressing processes in order to maintain a competitive advantage to other OEM’s within the market. Our company’s culture of team spirit & mutual respect with a focus on fair treatment helps us to embrace our multi-cultural affiliation with Magna International, and supports our mission through process efficiency and competitive product pricing. Furthermore, the culture at Kamtek focuses on Job Security, with employees being given the opportunity for continuous training, advancement within the skill/trade, and potential for growth within our safe work environment. We offer Employee Equity and Profit Participation programs which increase our employees’ ownership within the company. Kamtek, part of Cosma International and a division of Magna International, represents the the most diversified automotive supplier in the world. We design, develop and manufacture automotive systems, assemblies, modules and components, and engineer and assemble complete vehicles, primarily for sale to original equipment manufacturers (OEMs) of cars and light trucks in our three geographic segments - North America, Europe, and Rest of World (primarily Asia, South America and Africa). Our capabilities include the design, engineering, testing and manufacture of automotive interior systems; seating systems; closure systems; metal body & chassis systems; mirror systems; exterior systems; roof systems; electronic systems; powertrain systems as well as complete vehicle engineering and assembly. We have a global presence in order to support our customers on a worldwide basis, consisting of 136,000 employees in 319 manufacturing operations and 85 product development, engineering and sales centers in 29 countries on four continents as of Q2 2015. ##### Job Introduction The Process Engineer is responsible for the die cast operations and oversees and leads in their implementation and continuous improvement. ##### Major Responsibilities Responsible to support all aspects of Aluminum Die Casting from melting through final machining. Additionally, the Process Engineer will be responsible for new projects, capital improvements, and overall process efficiency. 1)Follow and enforce all plant safety rules and policies. 2)Understand and promote Magna’s philosophies (Magna Operational Principles, Corporate Constitution and Employee’s Charter). 3)Utilize statistical methods (including DOE) to optimize casting process parameters to improve Net Casting Rate. 4)Calculate gate areas using PQ2 methods, runner area and cross-sections to optimize part quality, yield and Net Casting Rate. 5)Collaborate 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 Efficiency. 6)Sample die cast tooling both in plant and at external plants and suppliers. 7)Analyze scrap and determine reason or root cause of problem. 8)Perform cycle time analysis, determine bottleneck operation and implement counter-measures to improve Net Casting Rate 9)Document critical die cast process parameters – make accessible at point of use. 10)Control revision level of process parameters and equipment programs. Responsible to back-up equipment programs. 11)Document all die cast process changes and maintain change history. 12)SME: Furnaces, Die Cast Machine, Die spray system, Die Cast automation 13)Manage equipment suppliers. Manage timing and budget. 14)Review production process to measure compliance to the standard parameters. 15)Promotes good housekeeping (5S) 16)Perform other duties as required. ##### Knowledge and Education EDUCATION: High School Diploma or GED required; Bachelor of Science - Mechanical/Industrial Engineering or 5-10 years of related experience in high pressure die castings in the automotive industry TECHNICAL TRAINING: Die Design, Runner & Cooling Design experience preferred, Catia and 3D CAD experience preferred, Minitab OTHER: Strong Computer and Microsoft Office Skills (Excel, Word, PowerPoint, Outlook), Lean Manufacturing background & Six Sigma preferred, Knowledge of PLCs, Robotic Programming, Root Cause Analysis, Statistical Problem Solving & DOE ##### Work Experience Minimum of 1 year manufacturing, Die Casting Preferred ##### Skills and Competencies * Must possess good interpersonal communication skills, including the ability to communicate technical information to a non-technical audience * Excellent oral and written communication skills * Team skills * Ability to work in a fast-paced work environment * Flexibility to travel in North America and abroad ##### Work Environment This position mandates you to wear Personal Protective or Safety Equipment such as Safety Shoes, Glasses, Gloves, Hearing Protection, Hard Hats, & and that all jewelry will be removed while on production/ manufacturing floor. Daily, for short periods of time you could be working around extreme high temperatures (above 900 ° F/ 270C). *Group:* Cosma International *Division:* Kamtek *State/Province/County:* Alabama *City:* Birmingham *Job Type:* Regular