Automotive Manufacturing Program Manager - Casting

About this role

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What we offer: At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are.

Group Summary: Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Job Responsibilities:

Position Summary: The Automotive Manufacturing Program Manager is responsible for leading and coordinating customer programs from quotation, development, tooling, launch, and production readiness through full production support. This role serves as the primary interface between the customer, engineering, quality, operations, supply chain, tooling, and plant leadership teams to ensure programs are delivered on time, within budget, and in alignment with customer requirements. The ideal candidate will have strong automotive manufacturing program management experience, with preferred experience in aluminum die casting, high-pressure die casting, machining, tooling, and new product launch activities.

Essential Duties and Responsibilities • Lead assigned automotive manufacturing programs from award through launch, production ramp-up, and ongoing production support. • Develop, maintain, and communicate program timing plans, milestones, deliverables, open issues, and risk mitigation plans. • Serve as the primary customer contact for program timing, technical deliverables, launch readiness, engineering changes, commercial issues, and program status updates. • Coordinate cross-functional activities with engineering, quality, production, maintenance, purchasing, logistics, finance, tooling, and plant operations teams. • Manage APQP activities, including feasibility reviews, design reviews, process flow, PFMEA, control plans, gage planning, capability studies, run-at-rate activities, PPAP submissions, and customer approvals. • Track tooling, equipment, fixtures, gauges, packaging, EDI requirements, material readiness, and supplier deliverables to support successful program launch. • Support engineering change management by evaluating timing, cost, quality, material, tooling, and production impacts. • Monitor program budgets, capital expenditures, tooling costs, material costs, and change requests to ensure financial targets are achieved. • Identify bottlenecks, launch risks, capacity constraints, quality concerns, and production roadblocks; lead corrective actions to keep programs on track. • Coordinate prototype builds, pre-production trials, process validation, PPAP runs, and launch readiness reviews. • Support customer visits, audits, launch meetings, technical reviews, and issue-resolution activities. • Ensure compliance with applicable customer-specific requirements, IATF 16949 standards, ISO requirements, internal quality systems, and company procedures. • Prepare and present program status reports to customers, leadership, and internal stakeholders. • Provide ongoing support to manufacturing operations after launch to ensure a smooth transition into stable production. • Perform other related duties as assigned.

Die Casting Experience Preferred Preferred candidates will have hands-on or program leadership experience in aluminum die casting or high-pressure die casting environments, including knowledge of die design, tool build and tryout, casting process development, trim operations, machining, leak testing, heat treatment, shot monitoring, scrap reduction, die maintenance, and process capability improvement. Familiarity with casting defects, root cause analysis, and corrective actions related to porosity, soldering, flash, dimensional variation, cold shuts, and surface quality is highly desirable.

Required Qualifications • Bachelor’s degree in Engineering, Manufacturing, Business, Operations Management, or a related field; equivalent experience may be considered. • Minimum of 5 years of experience in automotive manufacturing, program management, launch management, engineering, quality, or operations. • Experience managing new product launches, engineering changes, tooling projects, and customer program deliverables. • Working knowledge of APQP, PPAP, PFMEA, control plans, SPC, MSA, 8D problem solving, root cause analysis, and corrective action processes. • Ability to read and interpret engineering drawings, specifications, GD&T, customer requirements, and technical documentation. • Strong project management skills, including timeline development, critical path tracking, budget management, risk management, and cross-functional follow-up. • Strong communication, leadership, organization, and customer-facing skills. • Proficiency with Microsoft Office, project management tools, ERP systems, and customer portals. • Ability to work in a fast-paced manufacturing environment and manage multiple priorities simultaneously.

Preferred Qualifications • Experience with aluminum die casting, high-pressure die casting, machining, tooling, or automotive structural/component manufacturing. • Experience working with OEMs or Tier 1 automotive suppliers. • Knowledge of IATF 16949, ISO 9001, customer-specific requirements, and automotive quality systems. • PMP, Six Sigma Green Belt or Black Belt, CQE, or related certification. • Experience with lean manufacturing, continuous improvement, value analysis/value engineering, and cost reduction initiatives. • Experience supporting EV, powertrain, chassis, body structure, or safety-critical automotive components.

Key Competencies •

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