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Senior Forge Process Engineer

2 months ago

Wilmington, Massachusetts, United States Tecomet, Inc. Full time
Job Overview

Position: Advanced Manufacturing Engineer - Forge

The Advanced Manufacturing Engineer - Forge is responsible for spearheading and facilitating the development of forging processes for medical device products throughout the organization. This role involves overseeing the technical elements of new initiatives and products to ensure successful launches, evaluated through critical metrics such as safety, profitability, waste reduction, quality assurance, and manufacturing efficiency.

This position must be executed in alignment with Tecomet's core principles of continuous improvement, customer-centric innovation, and a culture that prioritizes success, while also adhering to the company's financial and performance objectives.

Key Responsibilities:

  • Design and optimize forging processes for medical device products.
  • Calculate die cavity volumes considering thermal expansion, finishing, and dimensional specifications.
  • Collaborate with the design team on the creation of dies and tools.
  • Provide guidance to forge personnel during the development and production phases of all forging products.
  • Review and manage all metallurgical data received from testing vendors.
  • Enhance existing products to achieve cost reductions and minimize forging defects.
  • Lead the technical aspects of new program (NPI) development and projects to ensure successful launches, in accordance with internal APQP processes, while striving to meet key performance indicators including lead-time, safety, profitability, waste, quality, and manufacturing efficiency.
  • Support legacy product lines to maintain established quality, delivery, and financial performance metrics.
  • Assist with furnace surveys and calibration/validation tasks.
  • Drive and support engineering change orders (ECO) and process modifications.
  • Contribute to CAPA root cause analysis activities as necessary.
  • Assist in the development of Quote & Cost Modeling related to forging processes.
  • Facilitate solutions through interdepartmental collaboration on forging manufacturing challenges.
  • Adhere to established company and departmental regulations while maintaining quality standards.
  • Support strategic advancements in manufacturing processes through Strategic Deployment and Lean Daily Management initiatives.
  • Perform additional duties or special projects as assigned by the engineering manager.

Qualifications:

Educational Background:

  • A Bachelor's degree in one of the following fields is required: Forge Engineering, Mechanical Engineering, Materials Science Engineering, Manufacturing Engineering, Industrial Engineering, or Chemical Engineering.
  • A minimum of 5 years of experience directly related to the development and operation of forging processes.

Skills and Competencies:

  • Exceptional communication and interpersonal abilities.
  • Capacity to work autonomously as well as collaboratively within a team.
  • In-depth knowledge and understanding of GD&T principles.
  • Advanced expertise and substantial experience with near-net shaped forging processes.
  • Familiarity with specialty alloys, including Titanium, Stainless Steel, Cobalt Chrome, and others.
  • Understanding of forging raw material preparation techniques.
  • Knowledge of forging preform processes such as drawing, bending, and glass-coating.
  • Experience with blasting and scale removal methods, e.g., acid-etching.
  • Preferred experience with Hot Forming forging processes.
  • Preferred experience with manufacturing automation in a forging context.
  • Familiarity with inspection equipment and its applications.
  • Proficiency in CAD Software such as Siemens NX (Unigraphics, SOLIDWORKS, or similar).
  • Knowledge of Deform software or equivalent.
  • Understanding of Lean Manufacturing Principles.
  • Familiarity with Gage R&R capability studies, SPC, FMEA, or Six Sigma methodologies.

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