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DCM Setter Operator

Job Number:  42346
Group:  Cosma International
Division:  Cosma Casting UK
Job Type:  Permanent/Regular

Telford, GB

Work Style: 



Job Number: 42346 
Group: Cosma International  
Division: Cosma Casting UK 
Job Type: Permanent/Regular 
Location: TELFORD 


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

Responsible for setting up and adjusting various sizes of dies into Buhler Die Cast Machines and Trim presses to ensure parts are produced within specification. Perform any necessary die adjustments at set ups and to check accuracy during production. You’ll have experience with Buhler Die Cast Machines, Trim Presses and ABB robots and be able to set, configure, adjust and operate DCM machines. Being a core member of the production team and you will support in ensuring a safe working environment, and customer quality and satisfaction expectations are met.


Key Responsibilities

This role entails but is not limited to: -


  • Ensure that all dies are pre-staged at the machines and set according to the set-up sheets ready to be used for production.
  • Identify where remedial work might be required by support functions or ensure safe return of the dies to dedicated storage location at the end of the production run.
  • Leading planned / unplanned tool changing of Die Cast machines to ensure timely production against the plan.
  • Lead changeover activities and utilising SMED methodology to structure organised reduction of changeover times and provide detailed changeover report with concerns to production supervisor
  • Co-ordinate changeover activities with other stakeholders i.e., toolroom to ensure die availability on pre-heat station against the production plan
  • Conduct daily backup tooling audit to ensure tooling and equipment is available if needed to complete the changeover if primary tooling is unavailable
  • Be competent in running high pressure die casting machines, recovery of ABB robots from an emergency stop position
  • Perform TPM activities as needed and directed, such as, but not limited to cleaning, oiling and lubricating machines.
  • Check machine operation is within expected and set parameters and correct any out of conditions setting and/or report faults to the production supervisor or process engineering team.
  • Engage in CCUK continuous improvement initiatives (MAFACT) through identification and implementation of improvement activities that demonstrates measurable improvements in cycle time, work content reduction or workplace organisation.
  • Promote the companies HSE policies across the department and plant

Key Qualifications/Requirements

Essential: Proven

  • Proven production experience in Die casting machine setting and operating i.e., Buhler DCMs
  • Tool setting experience
  • Knowledge of SMED/QCO and business improvement tools and methodology
  • Experience of practical problem solving
  • 5S and workplace organisation methodology
  • Licensed operation of overhead crane
  • Understanding of KPI’s to drive performance
  • ABB robot operation and basic programming


  • Striko Furnaces experience
  • IOSH Managing Safely Qualification
  • Tier 1 automotive supply chain experience
  • Current FLT license
  • Experience of training of team members
  • Understanding of OEE and TPM

Additional Information

Personal Attributes:

  • Good problem-solving skills
  • Confidence to challenge the status quo
  • Target driven
  • Work collaboratively to achieve project/company goals
  • Ability to work in a fast paced environment
  • Good communicator both written and verbal
  • Ability to work under pressure
  • Organised and able to multi-task
  • Proactive in approach with a “can do attitude”
  • Valid Driving Licence
  • Self-motivated
  • Analytical approach
  • Ability to challenge/reason their point of view at all level
  • Logical approach
  • Eligibility to work in the UK

Work Environment:

  • Plant conditions necessitate exposure to heat, cold, dust, hot objects, and loud noises within our manufacturing environment. Full Health and Safety training and PPE provided for all conditions.

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