Sr. Process Engineer, Castings, Cybercab (Night Shift)

What to Expect

The Senior Process Engineer owns and controls the high-pressure die casting (HPDC) process for aluminum automotive giga-casting, including metal delivery, shot profile development, die thermal management, spray and extraction cycles, part removal, trimming, and secondary operations. This role sets and drives key manufacturing KPIs, optimizes existing processes, and partners cross-functionally to launch, qualify, and continuously improve casting processes, equipment, and work standards.

What You’ll Do

• Set, track, and drive KPIs for Quality, Safety, Rate, Downtime, and process count
• Identify and implement process and line improvements to optimize factory performance
• Partner with Manufacturing, Design, MPI, and other teams to define, qualify, and document new processes
• Support Engineering and Manufacturing through 5S, Lean, material handling, line layout, and safety work
• Apply lean tools such as VSM, PFMEA, line balancing, and 5S for continuous improvement
• Own the full HPDC process, including metal delivery, shot profiles, thermal management, spray, extraction, trim, and secondary operations
• Analyze process and production data to improve capability, prevent defects, and stabilize casting quality
• Lead CI initiatives for quality, uptime, cost, and safety, working with Controls, Maintenance, Quality, Tooling, and Operations
• Support new tool launches with DFM input and initial casting trials
• Use Ignition, thermal system, die lube spray, VDU, and FANUC robot knowledge to monitor, set up, and troubleshoot process and equipment issues

What You’ll Bring

• Degree in Mechanical, Manufacturing, Metallurgical Engineering, or a related technical field, or equivalent experience
• 5–10 years of hands-on engineering experience in HPDC or foundry environments
• Strong knowledge of aluminum or magnesium metallurgy, heat treatment, machine capability, and secondary operations
• Proficiency with MAGMA, Flow-3D, or ProCAST casting simulation software
• Proficiency with NX, CATIA, or Solid Works CAD
• Strong command of APQP, PPAP, FMEA, and DOE
• Desired experience with IDRA 6100 and 9000 ton machines for aluminum giga-casting
• Knowledge of VDU dosing systems for cycle time control and issue tracing
• Understanding of FANUC robots for spray and part extraction
• Full understanding of Ignition, thermal system software, and die lube micro-spray/electrostatic spray systems for setup, trending, and troubleshooting