Sr. Manager- Foundry Process Engineer

Together, we move the world. As an international leading development partner and supplier to the automotive industry, we at MAHLE are passionate about developing innovative solutions for climate-neutral mobility of tomorrow. Our focus is on e-mobility and thermal management as well as further technology fields to reduce CO2 emissions, such as fuel cells or highly efficient, clean combustion engines that also run on hydrogen or synthetic fuels.

MAHLE generated sales of €11.7 billion in 2024. Employing just under 68,000 people at 135 production locations and 11 technology centers, the company is represented in 28 countries. (as at: 12/31/2024). Join our MAHLE team! #StrongerTogether

Your Contribution

• Collaborate with production & QC teams to align technical capabilities with customer requirements
• Identify, troubleshoot, and resolve process-related issues and casting defects in a timely manner, implementing corrective and preventive actions (CAPA). 
• Process Improvement: Develop, evaluate, and improve foundry processes for manufacturing metal castings, including mold making, core making, melting, pouring, and finishing.
• Work with Pattern shop team & provide guidance.
• Identify and implement process improvements to increase production efficiency, reduce scrap rates, minimize waste, and lower costs.
• Work closely with cross-functional teams, including quality control, production, maintenance, and R&D, to ensure smooth production flow and the successful integration of new technologies.
• Maintain up-to-date documentation of all process procedures, adjustments, and project validation activities, ensuring compliance with safety, environmental requirements.

Your Experience and Qualification

• BE/B. Tech. (Mech/Manufacturing engineering/Material)
• Minimum 15 -20 years’ experience in pattern shop & Cast-Iron Foundry process.
• Prefer the knowledge and experience of automotive components, like Camshaft, Crankshaft etc….
• Preference will be given for green sand & shell sand foundry experience.
• Knowledge of IATF 16949, GD&T, drawings
• Excellent organization time-management abilities.

MINIMUM REQUIREMENTS

• Ability to analyze 2D/3D component drawings and optimize those for castability (avoiding sharp corners, managing section thickness) to reduce defects.
• Expertise in 3D modeling and surfacing software (e.g., SolidWorks, NX, Creo) to design complex patterns, core boxes, and match plates.
• Expertise to design complex patterns, core boxes, and match plates by using 3D modeling and surfacing software (e.g., SolidWorks, NX, Creo).
• Ability of Pattern Allowances Calculation, Parting Line & Core Print Design, Mold & Core Material Selection, Pattern Shop Operations, Defect Analysis, Molding Process Familiarity etc.. 
• Ability to handle the pattern shop.
• Mastery in Green sand & shell sand Foundry - Expert knowledge of green sand & shell sand parameters (moisture, permeability, green strength, compactability) and their effects on casting quality.
• Leadership and interpersonal skills: to motivate and guide teams, build relationships, and manage conflict. 
• Capability to design and optimize gating and riser systems to reduce defects, improve yield, and ensure defect-free solidification.
• Experience using casting simulation software such as MAGMASOFT to predict solidification, porosity, and thermal stresses.
• Proven ability to identify, analyze, and resolve root causes of casting defects (e.g., shrinkage, porosity, inclusion, sand defects) using techniques like 8D, Fishbone diagrams, etc...

Our Offering.

We will provide a collaborative environment working on exciting assignments, along with ongoing personal & career development opportunities.

We encourage you to apply even if you don't meet every single requirement. You may just be the right candidate for this or other roles!

After receiving your online application, the interview process will typically be, once your profile will get shortlisted.

#DiversityMatters with our inclusive culture, we welcome applications from all social, religious & ethnical backgrounds, disabilities both mental and physical, identities (gender) and neurodivergent people.