Senior Process Engineer (Casting)

TL;DR

Senior Process Engineer (Casting): Developing, testing, and implementing new casting programs and manufacturing processes with an accent on foundry technology, tooling, and quality validation. Focus on optimizing production launches, analyzing casting defects, and ensuring system reliability through statistical tools and hands-on shop floor equipment management.

Location: Onsite in Warren, Michigan. Must be able to travel at least 50% of the time. No relocation benefits provided.

Company

A global leader in the automotive industry dedicated to redefining mobility through human-centered design, breakthrough hardware, and intelligent software.

What you will do

• Lead and support the development of manufacturing processes, equipment, and tooling for casting programs.
• Perform manufacturing validations, build plans, and PPAP procedures to support production launches.
• Analyze casting defects and optimize processes using statistical tools like DOE and Red X.
• Conduct non-destructive and destructive testing procedures for casting investigation and analysis.
• Collaborate with cross-functional teams including QC, Design, and Tooling to troubleshoot and implement solutions.
• Develop technical documentation including process flow diagrams, PFMEA, and TIS.

Requirements

• Must be authorized to work in the U.S. without company sponsorship.
• Must be able to work onsite in Warren, Michigan.
• 3+ years of professional experience in a manufacturing environment.
• 2+ years of experience in Low Pressure Die Casting, Precision Sand, or Semi-Permanent Mold.
• Demonstrated knowledge of foundry processes and aluminum chemistry.
• BS degree in engineering, metallurgy, computer science, or equivalent experience.

Nice to have

• Training in aluminum metallurgy and flow simulation software (Magma, Flow 3D).
• Experience with Giga/Structural castings or injection molds.
• Proficiency in 3D design software such as NX or Catia.
• Background in mechanical properties testing and problem-solving methodologies.

Culture & Benefits

• Commitment to an inclusive workplace fostering belonging and professional development.
• Comprehensive total rewards package supporting well-being at work and home.
• Opportunity to work on next-generation automotive hardware and safety features.
• Collaborative environment focused on driving meaningful change in transportation.