Rotor Balance Process Control: Lead, stabilize, and control the rotor balancing process (static and dynamic, including two-plane balancing) for aluminum rotor components, ensuring strict balance targets and tolerances are met.
Aluminum Die Casting & Foundry Management: Optimize high-pressure die casting (HPDC) and induction melting parameters (melting, injection pressure, speed, cooling, and solidification) to minimize porosity, density variations, and geometric defects that impact rotor balance.
Casting Simulation & Optimization: Set up, run, and interpret aluminum casting simulations (using MAGMA, ProCAST, or equivalent) to optimize fill, flow, porosity, and solidification behaviors.
Mold & Tooling Lifecycle Management: Manage, inspect, and maintain casting molds and tooling, ensuring preventive maintenance is performed, downtime is minimized, and tooling tolerances are preserved.
Quality & Metallurgical Analysis: Perform non-destructive testing (interpreting X-ray results for porosity, misruns, and inclusions), mass spectrometry for alloy composition analysis, and metallographic microscope analysis to identify microstructure defects.
Gauges & Measurement Systems: Implement and maintain specialized gauges, presses, and measurement devices to verify GD&T tolerances, aluminum density, and overall rotor quality.
Personnel Training: Train, coach, and certify production operators and technicians on rotor balance procedures, die casting operation, gauge usage, and reaction plans.
Technical & Quality Documentation: Continually develop, update, and validate DFMEA, PFMEA, Control Plan, Process Illustration, and Part Print (GD&T drawings), focusing on rotor-specific balance and casting variations.
SPC Strategy and Reporting: Implement and oversee the SPC strategy (sampling design, control charts, variability analysis, and Cp/Cpk – Pp/Ppk calculation) using Quality Works (or similar tools) and prepare monthly capability reports.
Monitoring and Improvement of Quality Metrics: Regularly monitor and optimize KPIs such as First Time Through (FTT) and Rolled Throughput Yield (RTY), focusing on reducing scrap by addressing common-cause variation.
Engineering Change Management and Reaction Plans: Lead Engineering Change Management (MTC) and structure robust reaction plans for rotor process deviations.
Problem Solving and Lean Manufacturing: Apply structured methodologies (Global 8D, Six Sigma, or equivalent) and Lean tools (Value Stream Mapping – VSM, 5Ss, SMED, etc.).
Process Audits: Actively participate in process and quality system audits (such as ISO 9001 and IATF 16949) to ensure full compliance.
Cross-Functional Collaboration: Work in synergy with Production, Maintenance, Quality, PTME, and external suppliers to resolve technical issues and meet project milestones.
Professional Reporting: Prepare professional-grade reports and presentations to clearly explain balance, casting, and metallurgical investigations to management and stakeholders.
Rotor Balancing: In-depth understanding of rotor balancing (static/dynamic, two-plane) and balance quality targets; practical experience using balancing machines and vibration analysis instruments.
Casting Simulation: Proficiency with aluminum casting simulation software (MAGMA, ProCAST) to analyze fill, flow, porosity, and solidification.
High-Pressure Die Casting (HPDC) & Foundry: Deep understanding of HPDC fundamentals, aluminum casting (gating, risers, porosity sources, defect management), and induction melting processes (induction furnaces, melting control, alloying).
Mold & Tooling: Mold/tooling design, reading mold drawings, mold tolerances, and tooling preventive maintenance/lifecycle management.
Analysis & Testing:
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Non-destructive testing (NDT): experience operating and/or interpreting X-ray results for casting defects.
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Mass spectrometry: knowledge of Optical Emission Spectroscopy (OES) or ion-based techniques (ICP-MS) for alloy composition.
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Metallography: microscope analysis for identifying porosity, aluminum defects, and interpreting microstructures.
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Aluminum density: understanding of density variations and their impact on weight, tolerances, and rotor balance.
Equipment & Tools: Experience working with presses (die casting and metal forming presses) and Quality Works (or similar quality data management software).
Quality & Engineering Standards:
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Proficiency in Geometric Dimensioning and Tolerancing (GD&T).
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Advanced ability to interpret technical drawings (Part Prints) and Process Illustrations.
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Mastery of Core Tools (DFMEA, PFMEA, Control Plan, MSA) and SPC / Process Capability (Cp/Cpk – Pp/Ppk).
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Structured problem-solving methodologies (Global 8D, Six Sigma, or equivalent).
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Lean Manufacturing tools (Value Stream Mapping, Poka Yoke, Error Proofing, SMED).
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Knowledge of ISO 9001 and IATF 16949.
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Ergonomics applied to balancing and manufacturing stations.
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Monitoring and improving quality KPIs (FTT, RTY).
