Technical Expert Low Pressure Casting
Pubblicato il 30-08-2026 - Optimal Personal & Organisation in Milano
We are seeking a highly experienced, hands-on specialist in Low Pressure Die Casting (LPDC) to support a manufacturing operation in Mexico. The expert will work directly with production, engineering, quality, maintenance, and tooling teams to stabilize processes, resolve complex casting issues, improve performance, and build sustainable technical capability within the local organization.
Tutti i candidati sono invitati a leggere attentamente la seguente descrizione del lavoro e le relative informazioni prima di candidarsi.
The Assignment
The role combines deep technical expertise with practical execution on the shop floor. The successful candidate will assess the current LPDC operation, identify the main technical and organizational loss drivers, establish robust process windows, and lead structured improvement activities through to measurable results. This is not a desk-based advisory position. Daily presence in the production environment, direct problem solving, and close cooperation with the Mexican team are essential.
Role Mission
Stabilize production. Improve process consistency, casting quality, output, and equipment availability across the LPDC value stream.
Solve complex casting problems. Identify root causes and implement durable countermeasures for recurring defects and performance losses.
Create technical standards. Define reliable process windows, operating standards, control methods, and escalation routines.
Develop the local organization. Coach engineers, supervisors, technicians, and operators so improvements remain effective after the assignment.
Key Responsibilities
Process Stabilization and Optimization
Assess the current LPDC process, equipment condition, material flow, tooling performance, quality results, and technical organization.
Develop and optimize robust process windows for melt preparation, metal temperature, die temperature, filling pressure, pressure curves, solidification, cooling, cycle time, and part removal.
Reduce scrap, rework, leakage failures, cycle-time losses, unplanned downtime, and process variation through structured improvement plans.
Support production during critical shifts, trials, ramp-ups, and recurring technical disruptions until stable conditions are achieved.
Use production data, SPC, capability studies, and designed experiments to validate causes and improvements instead of relying on trial-and-error adjustments.
Casting Defect Analysis and Metallurgy
Lead root-cause analysis for porosity, shrinkage, oxide inclusions, cold shuts, hot tears, cracks, leakage, distortion, dimensional instability, and surface defects.
Evaluate alloy chemistry, melt cleanliness, hydrogen content, density index, filtration, degassing, modification, grain refinement,
and furnace management.
Interpret findings from X-ray, CT, leak testing, thermal analysis, metallography, destructive testing, and dimensional inspection, where applicable.
Translate analytical results into practical corrective actions for process, tooling, equipment, material handling, and operator standards.
Tooling, Equipment, and Industrialization
Evaluate casting die design, gating and feeding concepts, venting, thermal balance, cooling circuits, coatings, and maintenance standards.
Work closely with tooling, maintenance, automation, furnace, and machine suppliers to eliminate chronic equipment- and die-related losses.
Support new product introduction, process validation, production trials, capacity improvement, and safe series-production ramp-up.
Contribute technical input to casting simulation, tooling modifications, machine specifications, and investment decisions.
Quality Systems and Technical Standards
Strengthen PFMEAs, Control Plans, work instructions, parameter control, reaction plans, and layered process audits for LPDC operations.
Lead or support structured problem solving using 8D, 5-Why, Ishikawa, Pareto analysis, DOE, and statistical methods.
Ensure that corrective actions are documented, verified, standardized, and sustained across shifts and relevant product families.
Support customer- and supplier-related technical discussions when advanced casting expertise is required.
Leadership and Knowledge Transfer
Act as the technical authority for LPDC topics while working collaboratively with plant leadership and functional teams.
Coach local engineers, technicians, supervisors, and operators through practical shop-floor training and joint problem solving.
Build clear ownership, escalation paths, technical review routines, and a repeatable problem-solving culture.
Communicate progress, risks, priorities, and support requirements clearly to local and international stakeholders.
Candidate Profil
Technical Background
Degree in Metallurgy, Materials Science, Mechanical Engineering, Manufacturing Engineering, Foundry Technology, or a comparable technical qualification.
At least 10 years of relevant experience in aluminum casting, including substantial hands-on expertise in Low Pressure Die Casting and high-volume series production.
Demonstrated success in stabilizing underperforming casting processes and achieving measurable improvements in quality, scrap, cycle time, yield, and equipment performance.
Deep practical knowledge of aluminum alloys, melt treatment, furnaces, LPDC machines, die thermal management, casting tooling, and defect mechanisms.
Strong command of APQP, PFMEA, Control Plans, SPC, process capability, 8D, and structured root-cause analysis; automotive experience is strongly preferred.
Experience with casting simulation, thermal imaging, X-ray/CT evaluation, metallography, or advanced process-data analysis is advantageous.
Personal and Intercultural Requirements
Strong shop-floor presence and the credibility to work effectively with operators, technicians, engineers, and senior management.
Pragmatic, analytical, and persistent approach to complex production problems, with a clear focus on implementation and sustainable results.
Ability to lead through expertise, influence, coaching, and structured follow-up without depending solely on formal authority.
High cultural sensitivity and the ability to build trust in an international and operationally demanding environment.
Fluent business English is required. Spanish is a strong advantage; German is beneficial but not essential.
Willingness and ability to work on-site in Mexico for an extended assignment. The exact assignment model and duration will be defined with the selected candidate.
Measures of Success
Transparent baseline. A fact-based assessment of the LPDC operation, critical loss drivers, risks, and prioritized actions is established early in the assignment.
Stable critical processes. Key products and production cells operate within defined technical windows, supported by clear standards and reaction plans.
Measurable performance gains. Scrap, rework, leakage, cycle-time losses, downtime, and process variation show sustained improvement.
Stronger technical capability. The local team can independently analyze issues, maintain process discipline, and continue structured improvement work.
Sustainable handover. Knowledge, standards, open actions, and responsibilities are transferred clearly before completion of the assignment.
Why This Assignment
This position offers an experienced casting professional the opportunity to create visible impact in a complex industrial environment. The expert will have direct access to plant leadership, substantial technical influence, and the ability to combine immediate operational problem solving with long-term capability building. xykwogc Assignment terms, start date, duration, and contractual structure will be agreed based on the selected candidate's availability and profile.