Senior Application Engineer

The Application Engineer Casting & Machining is a senior technical expert with over 10 years of experience in machining and casting. Your role involves process development, tooling selection, cost estimation, and part validation. You will have end-to-end ownership of new part development, from interpreting drawings to proving out parts on the shop floor. Your deep understanding of CNC machining, cast component handling, and practical troubleshooting will be crucial in achieving optimal performance. Key Accountabilities: - Plan, develop, and prove out new parts for production readiness. - Utilize machinist experience to support setup, trials, and process troubleshooting. - Optimize cycle times, tool selection, and first-pass yield for cast components. - Accurately estimate time and cost for machining new and existing parts. - Lead continuous improvement initiatives on process, quality, and technical capability. Key Responsibilities: Machinist-Level Technical Execution: - Perform and guide part setup, tool path verification, and fixture alignment. - Interpret engineering drawings and GD&T for machining accuracy. - Operate CNC machines during part trials to verify performance and fine-tune parameters. - Apply knowledge of feeds, speeds, tool paths, and cutting strategies for best results. New Part Development & Prove-Out: - Analyze new part drawings, casting models, and specifications. - Define machining strategy, setup plan, and tooling needs. - Prepare CAM programs and perform first part trials on machines. - Adjust parameters and validate process stability through measurements and inspection reports. - Create machining SOPs, setup sheets, and in-process control plans post validation. Casting and Machining Process Engineering: - Review machining allowances, identify potential casting defects that impact machining. - Plan operations and tolerances for SG iron, grey iron, aluminum, and steel castings. - Suggest improvements in casting design for better machinability and cost-effectiveness. Tooling and CNC Programming: - Select and standardize tooling based on material and cycle time targets. - Create, simulate, and validate CNC programs using CAD/CAM software. - Work closely with tool vendors for trials, optimization, and life improvements. Estimation and Process Planning: - Prepare detailed cost estimation based on machine hours, tool wear, fixturing, and manpower. - Evaluate and benchmark cycle times from trials vs. estimates and identify gaps. - Support pre-sales or development teams with feasibility inputs. Cycle Time and Yield Improvement: - Analyze and reduce idle time, unnecessary operations, and tool change delays. - Monitor First Pass Yield (FPY) and minimize rejection rates through process tuning. - Drive root cause analysis (RCA) for dimensional deviations or surface finish issues. Technical Team Mentoring and Floor Support: - Train and coach operators on setup, tool usage, and quality checkpoints. - Troubleshoot machining issues and guide the team during part transitions or new setups. - Maintain structured knowledge base including SOPs, tooling charts, and setup guides. Quality, Safety, and 5S: - Ensure all trial and production parts meet drawing tolerances. - Promote safe work practices and enforce proper PPE and SOPs. - Uphold 5S and discipline on the floor for a clean and efficient workspace. Key Performance Indicators (KPIs): - Successful New Part Prove-Outs (on-time, right-first-time) - Cycle Time Reduction (%) - First Pass Yield (FPY) - Estimation Accuracy vs Actual - Tooling Cost per Component - Kaizen Implementation - Operator Skill Enhancement & Cross-Training If you are interested, please forward your updated resume to recruiter.3@futuresandcareers.com Wishing you the best !!! Padmapriya Recruitment Consultant Futures And Careers,