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Work at the forefront of automotive innovation with ZF,
one of the world’s leading automotive suppliers.

Castings Engineer

Location: 

Livonia, MI, US, 48150

Req ID 26614 | Livonia Tech II, United States

  

We are looking for a new colleague in the Foundation Brakes Core Design Department at our location in Livonia, Michigan.

 

Responsibilities:

 

  • Conduct MAGMA analyses of ductile/grey iron brake components during development of new products or during change of existing products. Provide recommendations to design of components and design of foundry tooling to obtain optimal solutions with respects to function, weight, castability and price.
  • Conduct thorough and extensive MAGMA analyses of ductile/grey iron brake components (housings, brackets, DIH adaptors, rotors, hubs, etc.) through the design process, working in close collaboration with brake design engineers as they optimize parts for performance requirements, mass, castability and porosity avoidance.
  • Support the APQP team throughout the foundry supplier launch process.  Provide recommendations for gating and risers, support DFM (design for manufacturing) inputs recommended from the foundry and work with the design team for implementation.  
  • Review and approve foundry supplier pattern design and supplier casting simulation submission.  Work with foundry supplier to resolve any unacceptable risk to the program while meeting required quality and timing requirements.
  • Use collective results of above MAGMA analyses to identify generalities and best practice guidelines by product type.  Work with team to capture and document these guidelines through internal Knowledge Management system.
  • Working with Advanced/Core design team, identify best casting approaches for new design concepts (nonstandard types).  Support development through casting simulation and provide expert casting feedback to the design team.  
  • Participate in global casting team to apply best practices from region to region (NA/EU/AP) and to maintain common standards/methods between groups.
  • Provide expert casting feedback in support the Supplier Development Engineering team to resolve open foundry supplier quality concerns.  Assist in the review and approval of foundry supplier APQP activities and PPAP submission.
  • Support the development of casting database for production castings.  Identify best casting practices/casting cost to support future casting launches and identify savings in current foundry supply base
  • Work with foundry suppliers to introduce simultaneous engineering principles into the prototype casting process, removing latency/wait times to reduce prototype casting lead time.
  • Provide technical casting support to the Value Engineering team regarding their cost-down activities on current production parts 

 

Qualifications:

 

  • Extensive MAGMA expertise required in conducting analysis, interpreting results, and providing recommendations for casting design and gating improvements. 
  • Minimum of 10 years in-foundry experience in automotive Iron Casting industry, preferred experience in the production of Brake caliper housings and brackets.
  • Expertise in foundry production methods (e.g. patterns and molds, gating and riser design, parting line definition and drafting)
  • A balanced and solid background of engineering, manufacturing and some business travel to support workshops and supplier visits.
  • Preferred: Bachelor’s degree in Engineering.
  • Preferred: 3-5 years CAD experience, exhibit proficiency in NX or CATIA
  • Preferred: Aluminum casting experience
  • Preferred: Experience or exposure to cost analysis / value analysis

 

Be part of our ZF team as Castings Engineer and apply now!

 

 

DIVERSITY COMMITMENTTo harness the power of innovation, we invest in the development of diverse employees. We aspire to leverage the qualities and appreciate the unique competencies that each person brings to our company.Our company is committed to the principles of Equal Employment Opportunity and to providing reasonable accommodations to applicants with physical and/or mental disabilities. If you are interested in applying for employment with us and are in need of accommodation or special assistance to navigate our website or to complete your application, please contact us. Requests for reasonable accommodation will be considered on a case-by-case basis.ZF is an Equal Opportunity and Affirmative Action Employer and is committed to ensuring equal employment opportunities for all job applicants and employees. Employment decisions are based upon job-related reasons regardless of an applicant's race, color, religion, sex, sexual orientation, gender identity, age, national origin, disability, marital status, genetic information, protected veteran status, or any other status protected by law.Equal Employment Opportunity/Affirmative Action Employer M/F/Disability/Veteran

Our Commitment to Diversity

ZF is an Equal Opportunity and Affirmative Action Employer and is committed to ensuring equal employment opportunities for all job applicants and employees. Employment decisions are based upon job-related reasons regardless of an applicant's race, color, religion, sex, sexual orientation, gender identity, age, national origin, disability, marital status, genetic information, protected veteran status, or any other status protected by law.


Nearest Major Market: Livonia
Nearest Secondary Market: Detroit

Job Segment: R&D Engineer, Manufacturing Engineer, Engineer, R&D, Drafting, Engineering, Research