Process Engineer II

4 days ago

Butterworth, Penang, Malaysia Mattel (Malaysia) Sdn Bhd Full time $60,000 - $120,000 per year

The Process Engineer in the Die Casting Department is responsible for developing, optimizing, and maintaining die casting processes to ensure high-quality production, efficiency, and safety. This role involves cross-functional collaboration with design, quality, maintenance, and production teams to drive continuous improvement and support new product introductions.

Process Development & Optimization
  • Develop and establish standard operating procedures (SOPs) for die casting machines and related equipment.
  • Define and optimize process parameters (injection speed, pressure, temperature, cooling, cycle time, etc.) for stable and repeatable production.
  • Conduct DOE (Design of Experiments) and root cause analysis to improve casting quality and reduce rejection rates.
  • Collaborate with tooling engineers to improve die life, reduce flashing, and enhance mold design for manufacturability.
  • Analyze cycle times, scrap rates, and machine performance to improve throughput and reduce waste.
Production Support
  • Provide technical support to operators and supervisors for process troubleshooting and problem-solving.
  • Monitor real-time production data to ensure compliance with quality and efficiency standards.
  • Lead corrective actions for casting defects such as porosity, shrinkage, cold shuts, misruns, or surface defects.
  • Troubleshoot equipment and process issues to minimize downtime.
Continuous Improvement
  • Drive Lean Manufacturing and Kaizen initiatives within the die casting area.
  • Reduce scrap rates, energy consumption, and cycle times through systematic improvements.
  • Monitor and report key performance indicators (KPIs) such as OEE, scrap rate, and productivity.
Safety & Compliance
  • Ensure all processes comply with safety regulations, environmental standards, and company policies.
  • Conduct risk assessments and implement preventive measures for safe operations of die casting machines
Documentation & Reporting
  • Prepare and maintain process documentation, work instructions, and technical reports.
  • Track KPIs (OEE, scrap %, cycle time, downtime, cost per part, etc.) and report performance trends.

Qualifications, Skills & Experience

Diploma or Degree in Mechanical Engineering or a related field.

Minimum 3 years of relevant experience in process engineering, preferably in the manufacturing industry.

Technical Knowledge:

  • Basic knowledge of plastic injection molding and die casting processes.
  • Familiarity with Lean Manufacturing, Kaizen, or Six Sigma principles will be an added advantage.

Skills:

  • Strong problem-solving and analytical skills.
  • Good communication and interpersonal skills to work with cross-functional teams.
  • Ability to work independently and manage multiple priorities.
  • Proficiency in MS Office and exposure to CAD software is an advantage.

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