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Powertrain (Casting) Manufacturing Engineer

2 months ago

Livonia, United States Insight Global Full time

Minimum Requirements

  • Bachelor of Science/Engineering; MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science.
  • 5+ years prior experience with high pressure die casting, preferably for structural applications.
  • Working level knowledge of casting, post processing, and die development processes.
  • Working level knowledge of core making processes and materials.
  • Knowledge of the secondary operations associated with castings, including, but not limited to trimming, fettling, deburring, and quality checks.
  • Knowledge of both iron and aluminum alloys used for castings.
  • Understanding of MagmaSoft or other casting simulation software results.
  • Experience performing casting manufacturing feasibility assessments.
  • Foundry operational experience in casting manufacturing processes and process control.
  • Ability to travel both domestically and internationally. (Travel may be required from 25% - up to 80% of time)


Responsibilities:

  • Drive the New Model Launch of Complex Casting (NMLCC) process, which will provide a framework to enable the cross functional teams to create Program / Component specific plans, for the development and implementation of manufacturing feasible casting designs and processes resulting in parts that can be machined by standard and best practice methods in support of new Powertrain program product launches. Document this process using the NMLCC Process Development Log. These roles include and are limited to the following:
  1. Report out on the status of the NMLCC process through Delivery Team (integrator in GPDS , etc.).
  2. Provide technical support to Product Development (PD) Component Program Module Teams (CPMT's) and coordinate casting design between Product Engineering, PTME - Machining and external casting suppliers to assure ‘design for manufacturing feasibility’ of new Powertrain castings.
  3. Support new model program cost studies and projects.
  • Support the Digital Preassembly 5 (DPA5) process through the development of component Manufacturing Design Specifications (MDS) and Manufacturing Process Specifications (MPS). Complete Manufacturing Assessments.
  • Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering and supplier organizations.
  • Support supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of suppliers and subcontractors.
  • Provide support for casting prototype planning, process development and scheduling.
  • Support on-time quality prototype delivery of new Ford components at internal and external supplier facilities.
  • Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products.
  • Support Product Engineering in the selection and specification of component materials and test procedures.
  • Support Purchasing with the issuance of prototype and production tooling orders, following the Ford Tooling Procurement Management Process, as required.
  • Assist Ford manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.
  • Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of casting related productivity and quality issues and the development of external casting suppliers.