Machining Process Engineer

Job description

We are looking for a Machining Process Engineer passionate about cutting metallurgy, advanced metrology, and high-speed production line optimization. In this role, you will be the end-to-end technical owner of the machining process for major structural components (CGI/cast iron engine blocks, aluminum cylinder heads, or forged steel crankshafts), driving dimensional stability, the introduction of new tooling, cost-per-part (CPP) reduction, and the alignment between product blueprints and the statistical capabilities ( $C_p, C_{pk}$ ) of our CNC machining centers.

Responsibilities

Process Ownership and Dimensional Capability

Design, validate, and optimize machining processes (milling, deep-hole drilling, reaming, boring, and honing) to ensure critical engine features achieve micron-level tolerances and statistical capabilities ( Cp,Cpk≥1.67Cp, Cpk \ge 1.67 C p , C p k ≥ 1.67 ).

Tooling Management and Cost Reduction (Tooling & CPP)

Lead the selection, trial, and optimization of cutting tools (cemented carbide, PCD inserts for aluminum, and CBN for iron/CGI) in partnership with world-class tooling vendors (Sandvik, Kennametal, Mapal, Guhring). Develop tool life strategies, flank wear criteria, and regrind/reconditioning programs to systematically drive down Cost Per Part (CPP) without compromising quality.

Metrology Correlation and CMM

Interpret daily dimensional reports from Coordinate Measuring Machines (CMM), surface profilometers ( Ra,Rz,RkRa, Rz, Rk R a , R z , R k ) and air gauges. Translate geometric deviations into immediate work offset updates ( G54−G59G54-G59 G 54 − G 59 ), tool wear compensations, or mechanical adjustments to workholding fixtures.

Cycle Time Optimization and Throughput

Analyze cutting kinematics and non-cutting movements (air cuts) within numerical controllers (Siemens 840D / Fanuc), optimizing tool paths to eliminate bottlenecks and sustain target production line cadence (JPH).

Technical Documentation and Core Tools (APQP / FPS)

Author and audit live process documentation: Machining PFMEAs (failure modes: journal/bore misalignment, exposed porosity, stripped threads, harmonic chatter), Control Plans, Tool Layout Sheets, and Operator Instruction Sheets (OIS / JES).

Engineering Change Management

Plan and coordinate Plant Trial Runs (PTR) for new part number introductions, product engineering changes (WERS), or modifications in raw casting/forging stock.

Cutting Fluids and Industrial Washing Support

Monitor and optimize concentration, pH, and filtration of water-soluble coolant or Minimum Quantity Lubrication (MQL) systems, as well as parameters for industrial part washers and thermal/high-pressure waterjet deburring cells.

Qualifications

Bachelor’s Degree with a Professional License ( Cédula Profesional ) in Mechanical, Mechatronics, Metallurgical, Manufacturing, Industrial Engineering, or a related field. 3 to 5+ years of proven experience as a Process, Manufacturing, or Tooling Engineer on high-volume CNC machining lines in the automotive industry (hands-on experience in machining engine, transmission, chassis, or brake components is essential). Advanced / Fluent English (B2+ to C1).

Essential for daily communication with Product Engineering (Powertrain D&R in Dearborn) and US-based machine and tooling builders.