Process Engineer-1

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Process Engineer – High Pressure Die Casting

Primary Responsibilities

• Develop, optimize, and maintain HPDC processes for quality, productivity, and cost.
• Establish and optimize shot profiles, injection speeds, pressures, temperatures, and cooling parameters.
• Troubleshoot casting defects including porosity, flash, cold shuts, misruns, soldering, shrinkage, and dimensional variation.
• Optimize cycle times, scrap rates, OEE, and material utilization.
• Support die design, die trials, and new product launches.
• Perform root-cause analysis and corrective actions using structured problem-solving methods.
• Develop and maintain process parameters, standards, and work instructions.
• Use SPC and process data to monitor and improve process stability.
• Work closely with Quality, Tooling, Maintenance, Production, and Controls Engineering.
• Support PPAP, capability studies, DOE, and continuous improvement activities.
• Ensure processes meet safety, quality, and customer requirements.

Key Knowledge/Skills

• High-pressure die casting
• Die design and tooling
• Aluminum/magnesium/zinc casting
• Injection systems and shot profiles
• Casting defect analysis
• DOE and statistical analysis
• Root-cause/problem-solving methods
• Lean Manufacturing / Six Sigma
• SPC, Cp/Cpk, OEE
• Familiarity with die-casting machines, furnaces, robotics, and automation

In one sentence:
A HPDC Process Engineer is responsible for developing and controlling the casting process so the machine consistently produces high-quality parts at the required cycle time and cost.