Process Engineer - Die Cast

Job Title

Process Engineer

Aisin Automotive Casting Tennessee Inc.

Clinton, TN

Die Cast

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.

• 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.

• 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 such as Solid Works or 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; 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.