The
Role:
Reporting to Tooling Production Manager, the Tooling and
Process Development Engineer leads all tooling & process engineering
activities for the assigned part numbers and related components.
Responsibilities:
- Responsible
for Engineering of Casting dies for all assigned High Pressure Die-cast
components
- Proficient
in die design with optimized runner & gate, thermally balanced
inserts, and highest possible vacuum efficiency to produce structural
components using water free lube
- Manage
die suppliers using Project Management best practices during die build
programs, keeping project within time and budget
- Lead
die builds, design approvals and die buy offs from Tesla Tooling
Engineering
- Responsible
for supporting process development of all new dies produced for Tesla
Casting operation until production process parameters are established
- Create
tooling documentation and support process engineers with process
documentation for all new dies/inserts
- Create
required work instructions and documentation for all die related
activities including preventative maintenance, assembly, repair and the
tools that should be used for these activities
- Create
critical spares inventory with min and max order quantity
- Involve
in DFM process with Tesla product design team for new and existing parts
- Able
to provide simulation models and read simulation reports with good
understanding of flow simulation software such Flow 3D and Magma Soft
- Collaborate
with Materials Engineering on optimizing tooling performance by utilizing
applicable surface coatings and materials to improve die life and
reduce/eliminate soldering.
- Incorporate
design features that facilitate quick die change.
- Utilize
Poke Yokes to prevent errors & mistakes
- Perform
dimensional analysis; implement corrective actions to improve dimensional
capability. Complete understanding of casting tolerances and GD&T
- Involve
in maintenance of dies by providing Engineering support as needed
- Collaborate
with Tool & Die team to address all production issues related to
Tooling
- Maintain
die design/documents database with timely updates as needed
- Lead
ECO implementation for assigned dies until final approval
- Perform
thermal balancing of dies using thermal(Infrared) cameras and thermal
mapping
- Create
control plan working with quality department
- Continuous
improvement activities for dies and processes
- Create
and close of JIRA work tickets as needed
- Troubleshoot
systematically for downtime and scrap issues due to the die using RCA methods
- Establish
strong and positive working relationship with other departments
- Commitment
to be a strong team player
- Willing
and flexible to travel
- Willing
and excited to share work environment that includes office and
manufacturing plant floor
Requirements:
- Bachelor
of Science – Mechanical, Materials, Casting or Industrial Engineering
- Related
on the floor experience in the High Pressure Die-castings in the
automotive industry
- Proficient
in Die Design with experience in gating and thermal design
- Proficient
in 2D and GD&T
- Experience
with 3D modeling with proficiency in CATIA V5
- Experience
with flow simulation software
- Knowledge
in Lean Manufacturing
- Project
Management skills
