About us

We see a future where everyone can live and move without limitations. That's why we are developing technologies, systems and concepts that make vehicles safer and cleaner, while serving our communities, the planet and, above all, people.

Forward. For all.

Group Summary

Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Cosma Casting UK is an operating unit of Magna International, one of the world's premier global automotive suppliers. Magna's pioneering technology and creativity allows our customers to ask for solutions that lie beyond what they previously thought was possible.

• Leading the Product and Tooling Design Team in delivery of all suitable products and the tooling required to produce them.
• Overall leadership to ensure the product designs are suitable for manufacture, and that the proposed production methods can achieve the customer requirements.
• Ownership and management of suitable tooling specification documentation, creation of a standardized Statement of Requirements Packages for Tooling Purchases.
• Support RFQ Activities to source new and production running tools/Equipment.
• Oversee the Formal sign off for tooling/Equipment design, final acceptance, and ECM driven changes to the SOR.
• Own the data management system that ensures data chronology, sets suitable access levels and is linked with AME to ensure alignment with the SAP and ECM process.
• Implementation of best practice and lessons learned through the ECM process.
• Accountability to ensure tooling remains within the agreed budgets.
• Apply design for Manufacturability (DFM) principals to evaluate product designs and produce summary reports to support engineering and quoting activities.
• Identify tooling and equipment potential issues via the DFMEA Process and implement measures to design them out.
• Utilize product data management system to maintain CAD data for products, tooling, fixtures, manufacturing equipment and facilities.
• Project management of tooling suppliers. This may involve overseas travelling and working outside "normal" UK working hours, to cover time zone differences.
• Support continuous improvement activities through effective use of 3D and 2D CAD to propose product design changes, tooling improvements.
• Oversee the Design of die cast dies: Runner, Cooling, Vacuum systems etc. to ensure best part quality and optimize yield.
• Design features that facilitate quick die and equipment change
• Assist with Die Standards to: (1) Improve production performance i.e. net Casting Rate (2) Optimize casting yield and (3) Minimize tooling costs without compromising quality.
• Responsible for improving uptime and reducing maintenance costs of DC die & Trim dies and all downstream equipment.
• Participate in root-cause analysis and implement counter-measures.
• Utilize 3D FEA, Flow and Solidification analysis to improve designs.
• Complete understanding of casting tolerances, dimensional capability statistics and GD&T
• Maintain master tool drawings and facilitate access to Toolroom staff for all tooling maintenance - minimizing downtime and costs
• Calculate tooling clearances based on thermal expansion and minimum flow distances
• Implement POKE YOKE in tool design to prevent miss-assembly.
• Carry out Onboarding activities, Attendance and return to work reviews.
• Provide Status reports and updates for all activities to tooling Manager.
• Assign and manage workload for all Team Members.
• Assign and Manage Goals and perform PDR Reviews.
• Lead the team, ensuring individuals achieve their respective job descriptions and goals.

• Proficient with 3D SolidWorks and Catia software
• Die Design, Runner & Cooling Design experience.
• Proficient in Microsoft Office Packages
• Ability to effectively communicate and build relationships with customers

• ONC/HNC Apprenticeship or equivalent either in Mechanical or Electrical Eng'g
• Six sigma
• Root Cause Analysis
• Lean Manufacturing experience

• Good interpersonal skills with "hands on" problem solving expertise.
• Work collaboratively to achieve project/company goals.
• Ability to work in a fast-paced environment.
• Strong communicator both written and verbal.
• Ability in influence and manage stakeholders.
• Very organized.
• Strong leadership skills
• Work well within a team environment.
• Proactive in approach with a "can do attitude".
• Flexibility to travel overseas at short notice.
• Full Driving License.