Primary Responsibilities

• Develop, optimize, andmaintainHPDC processesfor quality, productivity, and cost.
• Establishand optimizeshot profiles, injectionspeeds, pressures, temperatures, and cooling parameters.
• Troubleshoot casting defectsincludingporosity, flash, coldshuts, misruns, soldering, shrinkage, and dimensionalvariation.
• Optimizecycle times, scraprates, OEE, andmaterial utilization.
• Supportdie design, dietrials, and newproduct launches.
• Performroot-cause analysisand corrective actionsusing structured problem-solving methods.
• Developand maintainprocess parameters, standards, and work instructions.
• Use SPC andprocess data tomonitor and improveprocess stability.
• Work closely withQuality, Tooling, Maintenance, Production, and ControlsEngineering.
• SupportPPAP, capability studies, DOE, and continuousimprovement activities.
• Ensure processes meetsafety, quality, andcustomer requirements.

Key Knowledge/Skills

• High-pressure diecasting
• Die design andtooling
• Aluminum/magnesium/zinc casting
• Injection systems andshot profiles
• Casting defectanalysis
• DOE and statisticalanalysis
• Root-cause/problem-solving methods
• LeanManufacturing / Six Sigma
• SPC, Cp/Cpk, OEE
• Familiarity with die-casting machines, furnaces, robotics, and automation

In one sentence:
A HPDC ProcessEngineer is responsiblefordeveloping and controllingthe casting processso the machineconsistently produces high-quality parts atthe required cycletime and cost.