Process Improvement & Engineering: Identifies scope of improvement against existing zinc die casting manufacturing processes; proposes solutions, seeks approvals, plans and executes improvement projects to enhance throughput, reduce cycle times, and eliminate waste.

Effectiveness is measured by reduction in process defects, cycle time improvements, and productivity metrics.

2.

Zinc Die Casting Process Parameter Optimisation: Develops,

monitors, and improves process parameters (injection pressure, shot speed, die temperature, cooling time, holding pressure, zinc alloy melt temperature, ladling volume, etc.) for all die casting machines to achieve consistent part quality with minimum variation. Effectiveness is measured by Cpk values, first-shot quality, and scrap reduction rates.

20%

3.

Machine Criticality & Capability Evaluation: Evaluates die casting machines on a 2x2 Criticality-Capability matrix at defined intervals;

initiates preventive/corrective actions to maintain uptime and process capability. Assesses die locking force, shot weight accuracy, and plunger tip condition. Effectiveness is measured by OEE scores and unplanned downtime reduction.

Quality Improvement & Rejection Reduction: Supports production to minimize rejection rates (porosity, cold shuts, flash, shrinkage)



through recent techniques or improvements to existing processes, ensuring optimum use of zinc alloy and machine resources. Effectiveness is measured by internal defect/scrap rates and material consumption vs. standard.

10%

5.

Documentation & Standardization: Creates, revises, and maintains

OMS/Work Instructions (WI), PFMEA, Control Plans, and process flow diagrams to ensure processes are repeatable, auditable, and compliant with IATF 16949. Documents zinc alloy composition, die lubrication specifications, and shot parameter sheets. Completeness and accuracy of documents is the primary measure.

15%

6.

Automation Implementation: Identifies opportunities for and implements automation solutions (robotic part extraction, in-line trimming/deburring,

automated die lubrication, in-line inspection) at the plant level to improve quality, reduce manual handling, and increase productivity. Measured by number of projects executed and resultant gains.

Drawing Review & NPD / Die Qualification Support: Reviews and interprets 2D engineering drawings and GD&T; callouts to validate tooling and die designs against product specifications. Supports NPD die trials

(T0/T1/T2) and process sign-off activities, including zinc alloy fill simulation review.

📌 Manufacturing Engineer Die Casting (Pune)
🏢 Shavish Group
📍 Pune