Process Engineer - Casting

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What we offer:

At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are.

Group Summary:

Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Job Responsibilities:

Job Summary

The Process Engineer is responsible for the die cast operations and oversees and leads in their implementation and continuous improvement.

The requirements listed below are representative of the knowledge, skill, ability and essential duties required to successfully perform this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Essential Duties and Responsibilities

• Utilize statistical methods (including DOE) to optimize casting process parameters to improve Net Casting Rate
• Calculate gate areas using PQ2 methods, runner area and cross-sections to optimize part quality, yield and Net Casting Rate
• 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 Rate
• Sample die cast tooling both in plant and at external plants and suppliers
• Analyze scrap and determine reason or root cause of problem
• Perform cycle time analysis, determine bottleneck operation and implement counter-measures to improve Net Casting Rate
• Document critical die cast process parameters - make accessible at point of use
• Control revision level of process parameters and equipment programs. Responsible to back-up equipment programs
• Document all die cast process changes and maintain change history
• SME: Furnaces, Die Cast Machine, Die spray system, Die Cast automation
• Manage equipment suppliers. Manage timing and budget
• Review production process to measure compliance to the standard parameters

Qualifications

• 5-10 years related experience in the high pressure die castings in the automotive industry
• Runner & Cooling Design experience
• BS - Mechanical/Industrial Engineering
• Knowledge of PLC, Robot programming, Root Cause Analysis, Statistical Problem Solving & DOE
• Lean Manufacturing background & Six Sigma preferred
• Good interpersonal skills and "hands-on" problem solving expertise
• Excellent oral and written communication skills
• Ability to work in a fast paced working environment
• Flexibility to travel in Ontario and abroad
• Fundamental computer skills using Microsoft Office suite, MS Project, AutoCAD and Minitab
• Must be able to understand written instructions

Work Environment

• Includes office and manufacturing plant
• Must be able to perform all essential functions as appropriate on the plant floor, in meetings, and with employees of all departments, management, customers and suppliers
• Provide support for three shifts and weekend production schedule as required by management
• Flexible hours and able to work additional hours as required

Work Authorization

• Applicants must be legally authorized to work in the United States at the time of hire. Candidates who currently hold valid work authorization under a TN or H-1B visa may be considered, provided they are authorized to work for this employer without requiring new or additional visa sponsorship. The company is unable to sponsor new employment-based visas or other immigration sponsorship for this position.

Other Considerations

• This job description in no way states or implies that these are the only duties to be performed by the employee occupying this position. Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their manager.
• A review of this description has excluded the marginal functions of the position that are incidental to the performance of fundamental job duties. All duties and requirements ar