Tooling Engineer - Casting

About the Role

Magna offers an engaging and dynamic environment where you can help develop industry-leading automotive technologies. As a member of our global team, you will have varied responsibilities and a wide range of development prospects tailored to your unique career path.

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

Responsibilities

• Promote and practice “safety first” by addressing hazards, defective equipment, or unsafe conditions within the department.
• Manage die cast die and trim tooling build, design, and spare parts to produce the highest Net Casting Rate.
• Design die cast dies, including runner, cooling, and vacuum systems, to ensure best part quality and optimize yield.
• Design die seals for best vacuum performance and leak prevention.
• Calculate and design cooling systems to ensure optimal part quality and cycle time.
• Design features such as vacuum systems, hydraulic actuated cores/slides, squeeze cores, and jet-cooled cores.
• Optimize tooling performance using coatings and materials to improve die life and reduce soldering.
• Design features that facilitate quick die change.
• Maintain a list of standard tooling components (cylinders, limit switches, prox switches, etc.).
• Develop and maintain die standards to improve production performance, optimize casting yield, and minimize tooling costs.
• Collaborate with the Tool Room Manager to develop and maintain a Tooling PM System.
• Improve uptime and reduce maintenance costs of die cast and trim dies through root-cause analysis and counter-measures.
• Analyze die IR images and improve die cooling for better thermal balance.
• Utilize 3D FEA, flow, and solidification analysis to enhance designs.
• Perform dimensional analysis and implement counter-measures to improve dimensional capability, with a full understanding of casting tolerances and GD&T.
• Collaborate with Machining Engineers to minimize machining stock and operations.
• Oversee tooling builds with tool shops, managing timing and budget.
• Maintain master tool drawings and provide access to Tool Room staff to minimize downtime and costs.
• Serve as a subject matter expert for DC Dies, Trim Dies, trim presses, and straightening tooling/equipment.
• Optimize shot component life to reduce cost per good shot.
• Calculate tooling clearances based on thermal expansion and minimum flow distances.
• Utilize poke yokes in tool design to prevent misassembly.
• Perform other duties as required.

Requirements

• 5-10 years of related experience in high-pressure die castings within the automotive industry.
• Die Design, Runner & Cooling Design experience.
• Proficient in 2D and 3D CAD.
• BS in Mechanical or Industrial Engineering.
• Knowledge of Root Cause Analysis.
• Lean Manufacturing background and Six Sigma preferred.
• Good interpersonal skills and excellent oral and written communication skills.
• Ability to work in a fast-paced environment.
• Flexibility to travel within Ontario and abroad.
• Fundamental computer skills using Microsoft Office suite, MS Project, and Minitab.
• Ability to understand written instructions.

Work Environment

• Primarily a manufacturing plant environment with temperature extremes, loud noise, and considerable tow motor traffic.
• Must be able to perform essential functions on the plant floor, in meetings, and with team members, management, customers, and suppliers.
• Job responsibilities include heavy lifting (up to 75 pounds) and working in confined spaces.
• Personal precision and hand tools are required.
• Able to work flexible hours and overtime.

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.