JOB DESCRIPTION

In this role, the Casting Manufacturing Engineer will define and deliver next-generation Unicasting manufacturing processes in support of future-model vehicle programs. Successful candidates will have a proven record of working with cross functional teams in the development and implementation of processes for aluminum high pressure die castings. Experience with high pressure die casting tooling maintenance and repair would be considered an asset.

The Unicasting Casting Process Engineer will be responsible for defining and implementing the casting process, from early program planning through facility launch. In this role, the engineer will have direct-line impact over the process development, bill of process and equipment identification and integration of Unicastings. This process is a new to Ford manufacturing process and must combine both technical and leadership capabilities to drive success. Ideal candidates must navigate and drive change in a complex internal environment, challenging the status quo as we define an all-new way of manufacturing vehicles.

• Work within a cross-functional manufacturing team towards development and execution of Unicasting manufacturing from early concept through facility launch.
• Advanced knowledge of casting manufacturing processes with hands-on experience.
• Leverage expertise from internal and external workgroups to drive strategy, resolve challenges, and deliver results.
• Utilize knowledge of quality processes and systems to meet stringent industry and customer requirements.
• Drive "Voice of Manufacturing" throughout product development lifecycle to ensure robust, feasible, and manufacturable casting assembly designs.
• Define and launch formal equipment and process standards for high pressure die cast tooling, casting equipment and post-processing cells.
• Lead scope-of-work development and competitive bidding exercises for Unicasting manufacturing systems.
• Drive continuous benchmarking of best-in-world practices for HPDC applications and utilize findings to improve Ford strategy.
• Work within a manufacturing engineering team to execute tooling design reviews, risk mitigation, commissioning processes, and launch handoff with a Ford manufacturing facility.
• Deliver on-time and on-budget launch for upcoming Unicasting programs.

• Bachelor of Engineering - Electrical or Mechanical Engineering
• 5+ years prior experience with high pressure die casting, preferably for structural applications.
• Knowledge of the high pressure casting process including melting, molding, and post processing
• Knowledge of the tooling die development process including maintenance and repair
• Knowledge of the secondary operations associated with castings, including, but not limited to trimming, fettling, deburring, machining, and quality checks.
• Knowledge of aluminum alloys used for casting structural and non-structural components.

• Ability to work in a production setting and aid in troubleshooting of equipment and processes.
• Excellent problem-solving skills with the ability to make decisions in a fast-paced, dynamic environment
• Posses the ability to address a variety of variables in situations where only limited standardization exists.
• Understanding of MagmaSoft or other casting simulation software results.
• Exceptional communication and interpersonal skills to present, persuade, and collaborate at all levels of the organization.
• Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority.
• Experience performing casting manufacturing feasibility assessments.
• Foundry operational experience in casting manufacturing processes and process control.

• Immediate medical, dental, and prescription drug coverage
• Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up childcare and more
• Vehicle discount program for employees and family members, and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year's Day
• Paid time off and the option to purchase additional vacation time.