Process Engineer (HPDC / Die Casting)

THE COMPANY

Barbachano International has been retained to seek a High Pressure Die Casting (HPDC) Process Engineer for our client, a global design, engineering, and manufacturing company that sells product solutions to the white goods, EV & Commercial industries, as well as other markets and after-sales channels. Our client manufactures more than 10,000 sophisticated controls for commercial and home appliances. Primary applications include controls for clothes washers and dryers, dishwashers, refrigerators, electric and gas cooking, ice makers, fluid dispensing, storage water heaters, gas valves for space/central heating, automotive/off-road temperature and fluid controls. Their global headquarters is located very near Chicago, Illinois, USA. The company employs over 5,000 employees in 14 countries, has 3 engineering centers, and 12 manufacturing locations.

THE POSITION

The mission of a High-Pressure Die Cast Process Engineer is to develop, optimize, and oversee high-pressure die casting (HPDC) processes to ensure the production of high-quality parts meeting production schedule while maximizing efficiency, reducing scrap and costs, minimizing downtime and meeting safety and environmental standards. This role involves innovation, continuous improvement, and problem-solving to achieve operational excellence and align with organizational goals. The Process Engineer interacts mainly with Quality, Production, Planning, and External Suppliers and reports to the Manufacturing Engineering Manager.  This position will work closely with cross-functional teams to drive production and program success.

Main Responsibilities:

• Provides assistance and direction to die cast teams
• Collaborate with plant and leadership team, customers, suppliers, and production floor personnel to identify and facilitate projects to improve key performance indicators
• Lead / participate in lean/six sigma process improvement initiatives and Kaizen events
• Monitors daily production and carry out troubleshooting, when needed
• Performs regular data collection of die cast productivity, rejects and machine efficiency
• Provides engineering support to all areas of manufacturing by establishing optimum die casting parameters and conditions, implementing product designs changes, developing process improvements, and providing engineered solutions to product and process problems
• Provides engineering support to die maintenance during die making, modification and maintenance and maintains die drawings to ensure that engineering revisions are reflected
• Support manufacturing operations with regards to device failure validation, root cause analysis, corrective action implementation
• Reviews customer rejects, implements action to prevent recurrence and meets with the customer if necessary to resolve problems
• Ensures smooth start of production (SOP) on new products
• Comply with all health, safety, quality and environmental standards
• Process Development and Optimization
• Design, implement, and refine high-pressure die casting processes to meet production goals.
• Develop process parameters (e.g., injection speed, pressure profiles, and cooling rates) to ensure consistent quality.
• Evaluate and select appropriate materials, tools, and equipment.
• Quality Assurance
• Collaborate with quality teams to analyze defects and implement corrective actions.
• Perform root cause analysis on casting-related issues such as porosity, shrinkage, or thermal stresses.
• Ensure products meet specifications and industry standards (e.g., ISO, IATF).
• Continuous Improvement
• Drive initiatives to improve cycle times, reduce scrap rates, and enhance energy efficiency.
• Implement lean manufacturing principles and Six Sigma methodologies in process improvement projects.
• Tooling and Equipment Management
• Support the design, procurement, and maintenance of dies, molds, and other critical tools.
• Collaborate with suppliers and toolmakers to ensure tooling meets operational requirements.
• Troubleshooting and Problem Solving
• Address daily production challenges, ensuring minimal downtime and high operational efficiency.
• Monitor and adjust machines and processes to resolve performance issues.
• Collaboration and Cross-functional Support
• Work with design, production, and quality teams to ensure seamless process integration.
• Provide technical support and training to operators and technicians.
• Safety and Environmental Compliance
• Ensure adherence to safety protocols and regulatory standards.
• Develop processes that minimize environmental impact, such as waste reduction and energy conservation.
• Data Analysis and Reporting
• Collect, analyze, and report data on key performance indicators (KPIs) like cycle time, yield, and defect rates.
• Use data to recommend and implement process improvements.
• Research and Development
• Stay updated on emerging technologies and advancements in die casting.
• Experiment with new materials, coatings, and equipment to enhance performance and efficiency.

THE CANDIDATE

• 3+ years’ experience in a similar die casting process engineer or similar hands-on position in manufacturing.
• Technical Knowledge: Strong understanding of high pressure die casting (HPDC) equipment, tooling, and materials science.  Experience in machinery TOSHIBA, ZITAI, ZAMAK and ITALPRESSE is highly preferred.
• Knowledge of CAD, modeling, print interpretations and dimensional evaluations required.
• Ability to operate a computer and its basic programs and various software, such as Microsoft Office and CAD programs.
• Strong Problem-Solving: Analytical skills for diagnosing and resolving complex process issues.
• Project Management: Ability to plan, execute, and manage process development and improvement projects. 
• Communication and Interpersonal Skills: Effective collaboration with cross-functional teams and suppliers.
• Attention to Detail: Precision in setting and maintaining process parameters.
• The ideal candidate will be self-directed, result-oriented, and a team player.
• Fluent in English and Spanish
• Bachelor degree in industrial engineering, materials engineering, materials science, mechanical engineering or a similar field.