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




current 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