Foundry Development Engineer

Key Responsibilities:

1. Develop new casting components from drawing to production.
2. Study customer drawings, specifications, and casting requirements.
3. Coordinate pattern, core box, tooling and process development.
4. Prepare and validate casting process parameters and process sheets.
5. Conduct trial runs, sample development and process validation.
6. Identify and resolve casting defects such as blow holes, shrinkage, misrun, cold shut, sand defects, and inclusions.
7. Conduct Root Cause Analysis, Why-Why Analysis and corrective actions for development issues.
8. Work closely with Production, Quality, Tool Room, and Customer teams during development.
9. Optimize yield, cycle time, material consumption and process cost.
10. Ensure new products meet customer quality and dimensional requirements.
11. Prepare development documents including APQP, Process Flow, PFMEA, Control Plan and Work Instructions.
12. Support PPAP documentation and customer sample approval.
13. Monitor development progress and ensure timely completion of projects.
14. Implement process improvements, Kaizen and cost-reduction initiatives.
15. Maintain development records, trial reports and lessons learned.