Senior Manufacturing Engineer- Die Casting

Key job responsibilities

• Own the commissioning, installation, startup, and ramp-up of HPDC production equipment
• Serve as the senior process engineering technical authority during facility launches and expansion projects, ensuring safe, efficient, and scalable production operations.
• Drive production readiness and operational performance metrics during launch and ramp-up phases, including safety, quality, throughput, OEE, scrap reduction, and cycle time optimization.
• Define, develop, validate, and sustain robust die casting process parameters from prototype through production while ensuring alignment between assumptions and demonstrated process capability.
• Develop and execute capital equipment strategies, including equipment specification, procurement, vendor selection, factory acceptance testing, installation planning, and production deployment.
• Drive cross-functional execution across production, tooling, automation, quality, maintenance, supply chain, facilities, and operations teams to ensure seamless program launches and stable production performance.
• Establish standardized production processes, operating procedures, process controls, PFMEAs, control plans, maintenance strategies, and operational documentation to sustain long-term reliability and repeatability.
• Drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and data-driven problem-solving methodologies to improve productivity, reduce variation, and optimize cost structures.
• Mentor and develop peers and junior engineers while fostering a culture of technical excellence, safety, and operational discipline.
• Act as the primary technical escalation point for complex production, tooling, and process challenges impacting performance and customer deliverables.
• Support technical reviews and provide technical expertise related to casting design, gating strategy, thermal management, alloy selection, solidification behavior, and more.
• Lead strategic technical engagement with die casting machine OEMs, tooling suppliers, automation integrators, and key production partners to ensure successful project execution and long-term operational performance.
• Collaborate with engineering and operations leadership to support long-range production strategy, capacity planning, facility expansions, and technology roadmaps.
• Champion world-class environmental, health, and safety standards across all production operations and launch activities.

Basic Qualifications

• Experience with Six Sigma, lean manufacturing, or experience with Six Sigma tools and Lean techniques
• Can communicate effectively with all levels of the organization
• Minimum 10 years of direct manufacturing engineering experience in high-pressure die casting environments, with emphasis on aluminum and/or magnesium casting technologies.
• Demonstrated success contributing to everything from commissioning to production of integrated HPDC operations.
• Deep expertise in die casting process development, parameter optimization, production stabilization, and operational troubleshooting.
• Prior experience influencing and driving execution across cross-functional teams in complex industrial environments.
• Strong experience in capital equipment strategy, production system design, facility startup, and industrial project execution.
• Extensive knowledge of die casting tooling strategy, die design collaboration, thermal management, vacuum systems, trimming systems, and automation integration.
• Experience driving operational excellence initiatives focused on safety, quality, cost, delivery, and productivity improvements.
• Experience with integrated systems including machining, automation, process monitoring, and ancillary equipment.

Preferred Qualifications

• Experience with Magnesium Thixomolding processes, structural HPDC applications, or advanced thin-wall aluminum casting technologies.
• Experience supporting multi-site production operations, plant turnarounds, or operational recovery initiatives.
• Prior experience acting as owner's representative during facility construction or expansion projects.
• Familiarity with site selection activities and utility planning.
• Experience with fully integrated casting, machining, leak testing, and assembly operations.
• Publishations, patents, or demonstrated technical contributions related to die casting process innovation or advanced production technologies.