Process Engineer - Die Cast

About the Role

A Die Casting Manufacturing Engineer at Aisin Automotive Casting Tennessee is 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.

Responsibilities

• Develop, optimize, and troubleshoot aluminum die casting processes to improve product quality, yield, and cycle time.
• Collaborate with toolmakers and maintenance teams to ensure that dies, tooling, and equipment are properly maintained and meet production requirements.
• 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.
• Manage and improve the auto deburring process, ensuring that parts are free of burrs, sharp edges, and other imperfections to meet required quality standards.
• Oversee trim pressing operations to remove excess material, ensuring the final product meets design specifications while maintaining process efficiency.
• Utilize distortion tables to monitor and correct any material distortion or warping during the die casting process, ensuring product quality and dimensional accuracy.
• Ensure that aluminum die-cast parts meet engineering specifications, quality standards, and customer requirements by applying effective measurement and testing techniques.
• Recommend and implement improvements to existing processes, equipment, and layouts, focusing on cost reduction, energy efficiency, and waste minimization.
• Lead root cause analysis for quality issues, process failures, and non-conformities to implement corrective actions and prevent recurrence.
• Maintain detailed records of process changes, trials, and troubleshooting activities. Generate process documentation, standard operating procedures (SOPs), and other technical reports.
• 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., SolidWorks, 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.