Process Engineer - Die Cast

Job Title: Process Engineer

Company: Aisin Automotive Casting Tennessee Inc.

Department: Die Cast

Location: Clinton, TN

Position Summary

As a Die Casting Manufacturing Engineer at Aisin Automotive Casting Tennessee, you will be 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.

Position Responsibilities

The incumbent is expected to perform the following functions that the company has determined are essential to this position:

Process Optimization: Develop, optimize, and troubleshoot aluminum die casting processes to improve product quality, yield, and cycle time.

Tooling and Equipment Maintenance: Collaborate with toolmakers and maintenance teams to ensure that dies, tooling, and equipment are properly maintained and meet production requirements.

Laser Marking: 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.

Auto Deburring: Manage and improve the auto deburring process, ensuring that parts are free of burrs, sharp edges, and other imperfections to meet required quality standards.

Trim Pressing: Oversee trim pressing operations to remove excess material, ensuring the final product meets design specifications while maintaining process efficiency.

Distortion Tables: Utilize distortion tables to monitor and correct any material distortion or warping during the die casting process, ensuring product quality and dimensional accuracy.

Quality Control: Ensure that aluminum die-cast parts meet engineering specifications, quality standards, and customer requirements by applying effective measurement and testing techniques.

Process Design & Improvement: Recommend and implement improvements to existing processes, equipment, and layouts, focusing on cost reduction, energy efficiency, and waste minimization.

Root Cause Analysis: Lead root cause analysis for quality issues, process failures, and non-conformities to implement corrective actions and prevent recurrence.

Documentation and Reporting: Maintain detailed records of process changes, trials, and troubleshooting activities. Generate process documentation, standard operating procedures (SOPs), and other technical reports.

Collaboration: 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.