Tooling Process Engineer wanted in Sterling Heights, Michigan to be responsible for the design and development, launch and production support of all Stamping Tooling at the division and group; Report to the Engineering Manager; Review customer prints for stamping feasibility and conduct Design for Manufacturing analysis that results in more cost-effective and robust manufacturing processes, while meeting or exceeding part design intent; Use analysis tools to optimize coil and Blank size; Perform initial forming analysis to confirm feasibility; Work in cross functional team to develop a robust stamping process, and propose press assignment, transfer or progressive process, material feed system for coils and Blanks, Press Scrap handling and transfer fingers; Support Purchasing as sole commercial responsible function, and negotiate and obtain competitive price for tooling; Participate in assigned program teams for quotation, development and serial production phase per Magna GPMS (Global Program Management System) process; Support all gate review deliverables, including managing tool design, build, and change activities and timelines to meet established deliverables; Perform simulation and analysis for optimal stamping tooling design using Auto Form; Prepare stamping drawing for each Stamping Operation with stack up to assure capable final stamped part that will be shipped as finished or used in subsequent CNC machining or Assembly operation; Lead tool design reviews with the tool shop, track build to approved tool print and track design changes to the original design by the tool shop, and involve cross functional team in the review as required; Collaborate with customers to develop the best DFM solution; Developing transfer simulations and optimize tool design and transfer finger design to maximize press speed; Collaborating with tool shop, quality and operations to consistently improve tool performance; Developing measurement plan for stamped part; Develop PFMEA and control plan for tool and support systems, for material movements through the process including fall-off; Design tool and support systems for single minute changeover; Develop standard work for change overs including balance charts, combination table and JESs where needed; Apply structured problem-solving to eliminate unplanned downtime and adjustment time reporting root cause and corrective action plans during operations meeting; Review and approve the tool forming simulation; Design and development of automotive stamping duties; Approve the design of various blanking dies, piercing dies, automotive brake presses and form dies; Perform calculations on sheet metal forming process using PROFIL; and perform other duties as required.
