Technical Expert Low Pressure Casting

We are seeking a highly experienced, hands-on specialist in Low Pressure Die Casting (LPDC) to support a manufacturing operation in Mexico. The expert will work directly with production, engineering, quality, maintenance, and tooling teams to stabilize processes, resolve complex casting issues, improve performance, and build sustainable technical capability within the local organization.

The Assignment
The role combines deep technical expertise with practical execution on the shop floor. The successful candidate will assess the current LPDC operation, identify the main technical and organizational loss drivers, establish robust process windows, and lead structured improvement activities through to measurable results. This is not a desk-based advisory position. Daily presence in the production environment, direct problem solving, and close cooperation with the Mexican team are essential.

Role Mission

· Stabilize production.  Improve process consistency, casting quality, output, and equipment availability across the LPDC value stream.

· Solve complex casting problems.  Identify root causes and implement durable countermeasures for recurring defects and performance losses.

· Create technical standards.  Define reliable process windows, operating standards, control methods, and escalation routines.

· Develop the local organization.  Coach engineers, supervisors, technicians, and operators so improvements remain effective after the assignment.

Key Responsibilities
Process Stabilization and Optimization

· Assess the current LPDC process, equipment condition, material flow, tooling performance, quality results, and technical organization.

· Develop and optimize robust process windows for melt preparation, metal temperature, die temperature, filling pressure, pressure curves, solidification, cooling, cycle time, and part removal.

· Reduce scrap, rework, leakage failures, cycle-time losses, unplanned downtime, and process variation through structured improvement plans.

· Support production during critical shifts, trials, ramp-ups, and recurring technical disruptions until stable conditions are achieved.

· Use production data, SPC, capability studies, and designed experiments to validate causes and improvements instead of relying on trial-and-error adjustments.

Casting Defect Analysis and Metallurgy

· Lead root-cause analysis for porosity, shrinkage, oxide inclusions, cold shuts, hot tears, cracks, leakage, distortion, dimensional instability, and surface defects.

· Evaluate alloy chemistry, melt cleanliness, hydrogen content, density index, filtration, degassing, modification, grain refinement, and furnace management.

· Interpret findings from X-ray, CT, leak testing, thermal analysis, metallography, destructive testing, and dimensional inspection, where applicable.

· Translate analytical results into practical corrective actions for process, tooling, equipment, material handling, and operator standards.

Tooling, Equipment, and Industrialization

· Evaluate casting die design, gating and feeding concepts, venting, thermal balance, cooling circuits, coatings, and maintenance standards.

· Work closely with tooling, maintenance, automation, furnace, and machine suppliers to eliminate chronic equipment- and die-related losses.

· Support new product introduction, process validation, production trials, capacity improvement, and safe series-production ramp-up.

· Contribute technical input to casting simulation, tooling modifications, machine specifications, and investment decisions.

Quality Systems and Technical Standards

· Strengthen PFMEAs, Control Plans, work instructions, parameter control, reaction plans, and layered process audits for LPDC operations.

· Lead or support structured problem solving using 8D, 5-Why, Ishikawa, Pareto analysis, DOE, and statistical methods.

· Ensure that corrective actions are documented, verified, standardized, and sustained across shifts and relevant product families.

· Support customer- and supplier-related technical discussions when advanced casting expertise is required.

Leadership and Knowledge Transfer

· Act as the technical authority for LPDC topics while working collaboratively with plant…