Product and Tooling Engineer

About us
We see a future where everyone can live and move without limitations. That's why we are developing technologies, systems and concepts that make vehicles safer and cleaner, while serving our communities, the planet and, above all, people.
Forward. For all.
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.
Position Summary:
Reporting to the Product and Tooling Engineering Supervisor the Product and Tooling Engineer is responsible for: -
Role Responsibilities:

• Review and validate designs for DCM Tooling to include High pressure dies, trim tools, spray heads and Robot EOA against tooling specifications, SOR and RFQ.
• Project management of tooling suppliers this may involve overseas travelling and working outside "normal" UK working hours, to cover time zone differences.
• Produce 2D product, tooling, fixture, equipment drawings to support manufacturing, quality and engineering activities.
• Part Feasibility reviews and apply design for Manufacturability (DFM) principals to evaluate product designs and produce summary reports.
• Complete understanding of casting tolerances, dimensional capability statistics and GD&T.
• Generate and develop CAD models of flow geometry for new parts i.e. Runners, vents and overflows and run simulations to Validate, Utilize MAGMA to provide insight and solutions to the casting process.
• Verify current Product Flow and Solidification software results to improve designs and define Runners, overflows and venting geometry to ensure best part quality and optimise yield.
• Review designs and Thermal simulations for cooling systems to ensure best part quality and optimal cycle time
• Generate SOR, RFQ to support engineering and quoting activities.
• Utilise product data management system to maintain and manage CAD data for product tooling, fixtures and manufacturing equipment.
• Support continuous improvement activities through effective use of 3D and 2D CAD to propose product design changes and tooling improvements
• Assist with Die Standards to improve tooling and minimise costs without compromising quality
• Participate in root-cause analysis and implement counter-measures
• Maintain master tool drawings and facilitate access to Toolroom staff for all tooling maintenance - minimizing downtime and costs.
• Develop, maintain and create standards required to ensure a smooth and efficient management of all data within the department.
• Manage all data transfers (incoming and outgoing) and ensure systems are in place to ensure this is formalised and managed accordingly.
• Use of CAD software to validate the product and create overlays to identify changes.
• Process Incoming data into workable formats.
• Identify and Map out part features which can be used across all departments
• Identify and support continuous improvements of the processes used within design and engineering department.
• Assist with department standardisation process.
• Validation of Flow and thermal analysis during production, work closely with toolroom and process engineers to capture lessons learned.
• Promote the companies HSE policies across the department and plant.

EXPERIENCE:
Essential

• Proficient with 2D and 3D CAD Software - SolidWorks and Catia.
• FEA/MAGMA Experience
• HPD Die Design, Trim Tools, Runner & Cooling Design experience
• Proficient in Microsoft Office Packages
• Ability to effectively communicate and build relationships with customers
• Familiar with ECN/ECM Process
• Understanding of die casting process
• Proficient in Microsoft Office Packages

Desirable

• ONC/HNC Apprenticeship or equivalent either in Mechanical or Electrical Eng'g
• Six sigma
• Root Cause Analysis
• Lean Manufacturing experience
• DFMEA and PFMEA

Personal Attributes:

• Good interpersonal skills with "hands on" problem solving expertise.
• Good organisational and planning skills to manage own time and to meet deadlines and objectives.
• Work well within a team and able to use own initiative.
• Work collaboratively to achieve project/company goals.
• Ability to work in a fast-paced environment.
• Strong communicator both written and verbal.
• Ability to influence and manage stakeholders.
• Very organised.
• Proactive in approach with a "can do attitude".
• Flexibility to travel overseas at short notice.
• Full Driving Licence.
• Eligibility to work in the UK

Work Environment:
Plant conditions necessitate exposure to heat, cold, dust, hot objects, and loud noises within our manufacturing environment. Full Health and Safety training and PPE provided for all conditions.