About the role
- Process Design and Optimization:
- Design and optimize the metal casting processes (e.g., sand casting, die casting, investment casting) to enhance production efficiency and product quality.
- Develop strategies to improve molding, melting, pouring, cooling, and finishing processes.
- Conduct process simulations and analyze outcomes to optimize parameters and reduce variability.
- Production Support:
- Work closely with production teams to troubleshoot and resolve any technical issues during the casting and molding processes.
- Provide ongoing technical support to operators and other foundry staff to ensure processes are followed accurately.
- Conduct regular process reviews to monitor production efficiency and identify improvement opportunities.
- Quality Control:
- Ensure all processes comply with quality standards, including dimensional accuracy, surface finish, and material properties.
- Establish and monitor quality control systems to detect defects early in the process.
- Lead investigations into process failures, product defects, and root cause analysis, and implement corrective actions.
- Cost Reduction and Efficiency Improvements:
- Develop and implement cost-saving initiatives, such as reducing material waste, energy consumption, and production downtime.
- Identify and lead projects focused on process automation, equipment upgrades, and overall process improvements.
- Optimize the use of raw materials, reduce cycle times, and improve overall equipment effectiveness (OEE).
- Safety and Compliance:
- Ensure compliance with safety regulations and standards specific to the foundry environment, such as handling molten metal, hazardous materials, and high-temperature processes.
- Promote a safety-first culture by implementing regular training, audits, and safety improvements.
- Assist in developing and enforcing health, safety, and environmental policies to protect workers and minimize risks.
- Collaboration and Teamwork:
- Work closely with foundry supervisors, maintenance teams, and other engineers to ensure smooth operation and continuous improvement.
- Assist in the development and training of staff on new processes, equipment, and best practices.
- Collaborate with the quality control team and design engineers to resolve product and process-related issues.
- Process Documentation and Reporting:
- Document process changes, developments, and troubleshooting efforts to ensure all modifications are tracked for continuous improvement.
- Prepare and present detailed reports on process performance, including key performance indicators (KPIs) related to quality, cost, and throughput.
- Maintain process documentation for audits and compliance with industry standards.
- Education: Bachelor's degree in Mechanical Engineering, Materials Science, Industrial Engineering, and diploma in mechanical engineer or a related field.
- Experience: At least 0 - 2 years of experience in process engineering, preferably in a foundry or manufacturing environment.
- Skills:
- Knowledge of foundry processes such as sand casting, die casting, or investment casting.
- Strong understanding of metallurgy, material properties, and casting defects.
- Familiarity with foundry equipment, such as furnaces, molding machines, and automated systems.
- Proficiency in process simulation software, CAD, and other engineering tools.
- Excellent analytical, troubleshooting, and problem-solving skills.
- Strong communication and teamwork abilities.
- Certification or experience with Six Sigma, Lean Manufacturing, or other process improvement methodologies.
- Familiarity with industry standards such as ASTM, ISO, and other casting-related specifications.
- Experience with metal melting processes, alloy compositions, and casting design.
- The position is typically based in a foundry or manufacturing plant environment, which can be noisy and high-temperature.
- Required to wear appropriate personal protective equipment (PPE), such as heat-resistant gloves, goggles, and safety footwear.
- May require occasional travel for training or to resolve site-specific issues.