Mechanical Design -Assistant Manager

Role & responsibilities

Casting Process Expertise

• Develop and optimize HPDC, LPDC, GDC, and Sand Casting processes.
• Establish robust manufacturing processes for new product development.
• Improve casting yield and reduce process variation.

Tooling Development & Validation

• Review tooling designs for manufacturability.
• Verify and validate new casting tools and dies.
• Conduct tool trials and production readiness assessments.
• Coordinate tooling modifications and improvements.

Tool Cost Estimation

• Prepare cost estimates for: PDC Dies, GDC Dies, Sand Casting Patterns, Core Boxes
• Analyze material, machining, heat treatment, and development costs.
• Support RFQ, budgeting, and supplier negotiations.

Tool Audit & Tool Life Monitoring

• Conduct periodic tool audits.
• Verify tool condition against design requirements.
• Assess die wear, cooling channels, vents, ejector systems, and parting line conditions.
• Monitor tool life and recommend preventive maintenance.
• Identify tooling improvements to reduce downtime and casting defects.
• Prepare tool audit reports with action plans.
• Ensure tooling inventory and maintenance records are updated.

Casting Defect Analysis & Resolution Analyze and resolve:

• Gas Porosity

• Shrinkage Porosity

• Blow Holes

• Cold Shuts

• Misruns

• Cracks

• Inclusions

• Flash

• Die Mismatch

• Soldering and Die Erosion

• Perform Root Cause Analysis (RCA).

• Implement corrective and preventive actions.

• Improve existing dies to eliminate recurring defects.

Other skills:

• Ability to read engineering drawings and CAD models. Preferred SolidWorks.
• Experience in Product data management software
• BOM management
• Tolerance Stack up analysis,

Preferred Experience

• 8-15 years in Foundry, Die Casting, or Casting Tool Development.
• Automotive, Industrial Equipment, Pump, Valve
• Experience working with tooling suppliers and foundries.

Preferred candidate profile

• Bachelors/Masters in Mechanical Engineering
• 5+ years in product design & development

kills:

• Knowledge of manufacturing processes & materials
• Tools: SolidWorks, AutoCAD, SAP ERP, PDM, Nano CAD, MS Office
• Strong project management & problem-solving skills
• Experience in electro-mechanical system integration

Key Competencies:

• Project planning & execution
• Communication & teamwork
• Vendor coordination
• Training & mentoring
• Adaptability & ownership