Tooling Engineer - 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:

Job Summary • The Tooling Engineer is responsible for and manages the cast and trim tooling used for production and prototypes. • The requirements listed below are representative of the knowledge, skill, ability and essential duties required to successfully perform this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Essential Duties and Responsibilities • Promote and practice “safety first” by immediately addressing any hazards, defective equipment, or unsafe conditions within the department • Manage die cast die and trim tooling build, design and spare parts to produce the highest Net Casting Rate. • Design die cast dies: runner, cooling, vacuum systems, etc. to ensure best part quality and optimize yield. • Design die seals for best vacuum performance and leak prevention. • Calculate and design cooling system to ensure best part quality and optimal cycle time. • Typical designs include: vacuum, seals, hydraulic actuated cores/slides, squeeze cores, jet-cooled cores, etc. • Optimize tooling performance by utilizing coatings and materials to improve die life and reduce/eliminate soldering. • Design features that facilitate quick die change. • Maintain list of standard tooling components (cylinders, limit switches, prox switches, etc.) • Develop and maintain die standards to: 1. Improve production performance (net casting rate), 2. Optimize casting yield and, 3. Minimize tooling costs / good casting. • Collaborate with Tool Room Manager to develop and maintain Tooling PM System. • Responsible for improving uptime and reducing maintenance costs of DC & Trim dies. Determine root-cause analysis and implement counter-measures. • Analyze die IR images and improve die cooling to improve thermal balance of DC die. • Utilize 3D FEA, Flow and Solidification analysis to improve designs. • Perform dimensional analysis, implement counter-measures to improve dimensional capability. Complete understanding of casting tolerances and GD&T. • Collaborate with Machining Engineer to minimize machining stock and machining operations. • Oversee tooling builds with tool shops. Manage timing and budget. • Maintain master tool drawings. Provide access to Tool Room staff for all tooling maintenance – minimizing downtime and costs. • SME: DC Dies, Trim Dies, trim presses and straightening tooling/equipment. • Optimize shot component life (shot component cost/good shot). • Calculate tooling clearances based on thermal expansion and minimum flow distances. • Utilize poke yokes in tool design to prevent mis assembly. • Perform other duties as required.

Qualifications • 5-10  years related experience in the high pressure die castings in the automotive industry • Die Design, Runner & Cooling Design experience • Proficient in 2D and 3D CAD • BS - Mechanical/Industrial Engineering • Knowledge of Root Cause Analysis • Lean Manufacturing background & Six Sigma preferred • Good interpersonal skills • Excellent oral and written communication skills • Ability to work in a fast paced working environment • Flexibility to travel in Ontario and abroad • Fundamental computer skills using Microsoft Office suite, MS Project and Minitab • Must be able to understand written instructions

Work Environment • The work environment is primarily manufacturing plant and is characterized by temperature extremes, loud noise and considerable tow motor traffic.  The individual must be able to perform all essential functions as appropriate on the plant floor, in meetings, and with Team Members, management, customers and suppliers. • Job responsibilities include heavy lifting (75 pounds) and working in confined spaces • Personal precision and hand tools required • Able to work flexible hours and overtime

​ Work Authorization • Applicants must be legally authorized to work in the United States at the time of hire. Candidates who currently hold valid work authorization under a TN or H-1B visa may be considered, provided they are authorized to work for this employer without requiring new or additional visa sponsorship. The company is unable to sponsor new employment-based visas or other immigration sponsorship for this position.

Other Considerations • This job description in no way states or implies that these are the only duties to be performed by the employee occupying this position.  Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their supervisor. • A review of this description has excluded the marginal functions of the position that are incidental to the performance of fundamental job duties.  All duties and requirements are essential job functions. • Some requirements may exclude individuals who pose a direct threat or significant risk to the health and safety of themselves or other employees. • Requirements are representative of minimum levels of knowledge, skills and/or abilities.  To perform this job successfully, the incumbent will possess the abilities or aptitudes to perform each duty proficiently.

Awareness, Unity, Empowerment: At Magna, we believe th

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