Develops cost effective and producible tooling, processing, and planning designs for the production of products in response to customer design parameters. Specifies casting mold configurations, gate and riser designs, casting process parameters, and process control plans. Participates in scrap and rework reduction plans. Applies the standard principles, theories and concepts of investment casting. Participates in product development projects.
DISTINGUISHING LEVEL CHARACTERISTICS:
LEVEL I: Under moderate supervision, develops production engineering plans for existing product lines.
LEVELII: Under limited supervision, provides technical leadership in the development of production and process engineering applications. Participates in the development of new Company products and services. Leads scrap and rework reduction plans and teams.
ESSENTIAL JOB DUTIES & RESPONSIBILITIES:
The following are exemplary essential job duties and responsibilities and are not intended to represent an all-inclusive listing of related essential functions of the position
PERFORM DEPARTMENT DUTIES IN A TIMELY AND EFFICIENT MANNER:
1) Evaluates customer design and process specifications, recommends and negotiates changes to enhance cost-effectiveness & producibility, and specifies tooling dimensions for in-house and subcontract tool designers.
2) Specifies casting mold configurations, gate and riser designs.
3) Establishes part route cards and specifies manufacturing work instructions.
4) Validates processes using statistical methods including process capability (CPK), and gauge repeatability and reproducibility studies.
5) Develops and manages engineering and first article production project schedules.
6) Work closely with Quality, Manufacturing and Production Control to ensure timely delivery of high quality castings.
7) Troubleshoots processes in order to define and implement corrective action.
8) Investigates new materials and processes technologies for investment castings.
9) Analyzes product failure data and laboratory test results in order to determine the root cause of a problem and develop solutions.
10) Monitors material and process performance and evaluates material deterioration and process control.
11) Designs and directs the testing and/or control of processing procedures..
12) Reviews new product plans and makes recommendations for material selection based on design objectives, such as strength, weight, heat resistance, electric conductivity and cost.
13) Explore new technologies that can further improve product quality and performance as well as reduce manufacturing and processing costs.
14) Participates in or leads scrap and rework reduction teams.
15) Works closely with tool makers in the design of wax injection tooling for new parts, including, and not limited to providing shrink and chem mill factors that would yield a dimensional conformant part.
16) Uses casting simulation software to optimize gating design on new and existing products
OTHER WORK AS REQUIRED/REQUESTED
May be assigned other work tasks that are generally within the scope and level of the position, and relative to the need for flexible Company operations.
May develop new products and/or improve the quality and reduce costs on current product.
MINIMUM & PREFERRED QUALIFICATIONS
Minimum: Bachelor degree in materials science, metallurgical engineering, mechanical engineering, or related discipline.
Preferred: Masters degree in above disciplines
Level II: 3 to 5 years of investment foundry or equivalent experience.
Level I: 0 to 2 years of investment foundry or equivalent experience.
Level II: 5 to 7 years experience in investment casting of ferrous and non-ferrous alloys. (titanium preferred)
Level I: 3 to 5 years experience in investment casting of ferrous and non-ferrous alloys. (titanium preferred)