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Tooling Engineer

Job Number:  39875
Group:  Cosma International
Division:  CCMi
Job Type:  Permanent/Regular




Job Number: 39875 
Group: Cosma International  
Division: CCMi 
Job Type: Permanent/Regular 



Group Description

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.


Role Summary

The Tooling Engineer is responsible for and manages the cast and trim tooling used for production and prototypes.

Key Responsibilities

  • Manage die cast die and trim tooling build, design and spare parts to produce the highest Net Casting Rate.
  • Design die cast dies: runner, cooling, vacuum systems, etc. to ensure best part quality and optimize yield. 
  • Design die seals for best vacuum performance and leak prevention.
  • Calculate and design cooling system to ensure best part quality and optimal cycle time.
  • Typical designs include: vacuum, seals, hydraulic actuated cores/slides, squeeze cores, jet-cooled cores, etc.
  • Optimize tooling performance by utilizing coatings and materials to improve die life and reduce/eliminate soldering.
  • Design features that facilitate quick die change.
  • Maintain list of standard tooling components (cylinders, limit switches, prox switches, etc.)
  • Develop and maintain die standards to: 1. Improve production performance (net casting rate), 2. Optimize casting yield and, 3. Minimize tooling costs / good casting.
  • Collaborate with Tool Room Manager to develop and maintain Tooling PM System.
  • Responsible for improving uptime and reducing maintenance costs of DC & Trim dies. Determine root-cause analysis and implement counter-measures.
  • Analyze die IR images and improve die cooling to improve thermal balance of DC die.
  • Utilize 3D FEA, Flow and Solidification analysis to improve designs.
  • Perform dimensional analysis, implement counter-measures to improve dimensional capability. Complete understanding of casting tolerances and GD&T.
  • Collaborate with Machining Engineer to minimize machining stock and machining operations.
  • Oversee tooling builds with tool shops. Manage timing and budget.
  • Maintain master tool drawings. Provide access to Tool Room staff for all tooling maintenance – minimizing downtime and costs.
  • SME: DC Dies, Trim Dies, trim presses and straightening tooling/equipment.
  • Optimize shot component life (shot component cost/good shot).
  • Calculate tooling clearances based on thermal expansion and minimum flow distances.
  • Utilize poke yokes in tool design to prevent misassembly.
  • Perform other duties as required.

Key Qualifications/Requirements

Additional Information

Work Environment

  • The work environment is primarily manufacturing plant and is characterized by temperature extremes, loud noise and considerable tow motor traffic.  The individual must be able to perform all essential functions as appropriate on the plant floor, in meetings, and with Team Members, management, customers and suppliers.
  • Job responsibilities include heavy lifting (75 pounds) and working in confined spaces
  • Personal precision and hand tools required 
  • Able to work flexible hours and overtime

Other Considerations

  • This job description in no way states or implies that these are the only duties to be performed by the employee occupying this position.  Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their supervisor.
  • A review of this description has excluded the marginal functions of the position that are incidental to the performance of fundamental job duties.  All duties and requirements are essential job functions.
  • Some requirements may exclude individuals who pose a direct threat or significant risk to the health and safety of themselves or other employees.
  • Requirements are representative of minimum levels of knowledge, skills and/or abilities.  To perform this job successfully, the incumbent will possess the abilities or aptitudes to perform each duty proficiently.
  • This document does not create an employment contract, implied or otherwise.

Nearest Major Market: Battle Creek
Nearest Secondary Market: Kalamazoo

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