Process Engineer - Die Cast

Process Engineer

Company:
Aisin Automotive Casting Tennessee Inc.

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., Solid Works, 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.