Manage assigned customer accounts by providing superior engineering support and foundry expertise on new and existing product designs. Develop a close working relationship with the customer's product engineering. Provide the manufacturing facility with the necessary assistance to launch a product on time including engineering support with 2D/3D product print/model analysis, APQP meetings, cost estimating, and MAGMA analysis. Act as the principal contact between the customer and the manufacturing facility to assure that the manufacture of the product meets functional requirements at the lowest possible cost. Support/Assist in quoting new products for assigned customer accounts.
Principle Duties and Responsibilities:
Work with Product Managers, Plant Managers and Process Engineers on accurate costing information with a focus on product to process fit.
Provide cost estimates for new products by reviewing specifications, tolerances, cast weight, core designs, and plate layouts for the lowest cost and best quality.
Work with customers to determine part geometry, parting line and print construction, and tolerancing with a focus on product to process fit.
Provide direct support to the customer on product design by visiting assigned customers' engineering departments.
Run filling and solidification simulations to develop optimal casting and gating designs.
Work with assigned customers on VA/VE projects and cost reductions.
Create 3D models and 2D drawings in Creo and AutoCAD to be approved by customers.
Manage all up-front product engineering aspects with assigned customers on new product launches.
Develop good working relationships with pattern shops for quoting and tool manufacturing.
Initiate/Participate in APQP and technical reviews.
Work with each foundry on continuous improvement projects related to product design, product manufacturing, and product processing.
Keep abreast of current technologies for cost reduction, production improvement and margin improvement.
Knowledge, Skill, and Ability Requirements:
Knowledge of green sand foundry/casting processes and practices (DISA preferred).
Knowledge of cast iron gating and risering design preferred.
Knowledge of multiple casting methods and capabilities preferred.
Knowledge of or experience working with both gray and ductile iron preferred.
Knowledge of ISO, IATF or QS quality systems preferred.
Experience working with tooling suppliers and customers.
Sound knowledge and understanding of geometric dimensioning and tolerancing.
Experience working with Microsoft Office Products (Excel, Word, etc.).
Ability to plan for and coordinate activities of multiple projects.
Ability to demonstrate good written and verbal communication skills for presentation and technical report writing.
Knowledge of company products and competitor products.
Approximately 30% travel required.
Working Conditions
The Product Engineer will reside in the office, however, will be in the plant occasionally. Must be able to adhere to conditions of the plant.
Education and Experience Requirements:
Degree in Mechanical Engineering or equivalent degree/experience.
3-5 years of foundry process engineering experience.
Excellent interpersonal skills.
Experience with 2D/3D CAD packages (Creo and AutoCAD preferred).
Possess skills in other engineering simulation related computer programs (MAGMA, FEA, ProCast, etc.) preferred.