Forging Process Engineer

Description

Tuwaiq Casting & Forging is seeking a technically proficient Forging Process Engineer to join the Process Engineering Division. Reporting to the Forging Technology Manager, this role is responsible for developing, validating, and improving open-die forging processes to achieve the required deformation, grain flow, dimensional accuracy, metallurgical properties, and productivity targets.

Key Responsibilities

Technical Operations

• Prepare forging routes, reduction plans, heating parameters, and handling instructions
• Develop Work Instructions (WI), Standard Operating Procedures (SOPs), and Travelers for production of parts in the Open-Die Forging Shop
• Define forging windows, deformation ratios, and critical control points
• Define ingot heating plans and open-die forging operation sequences
• Develop the Manufacturing Process Specification (MPS) with consideration of commercial feasibility
• Support simulation and interpretation activities for forging process optimization
• Investigate and resolve laps, cracks, underfill, dimensional issues, and poor metallurgical properties
• Support die and tooling review where applicable
• Support the development and implementation of plans for first article product production
• Coordinate with melting, heat treatment, machining, QA, and production teams
• Develop pre-production methods and provide technical support for prototype production and evaluation in collaboration with the factory
• Troubleshoot and drive continuous improvement of forging processes.
  
  

Quality

• Define product quality standards throughout the open-die forging process
• Prepare necessary EHS requirements for the Forging Shop
• Collaborate with quality control teams to address quality-related issues and implement corrective measures
• Analyse quality problems and establish countermeasures
• Support the establishment of the factory organizational structure
• Support the acquisition of required certifications and qualifications.
  
  

Process Optimization

• Identify opportunities for process improvements to enhance efficiency, productivity, and cost-effectiveness
• Analyse data and performance metrics to optimize forging parameters and maximize efficiency
• Implement new techniques, technologies, or equipment upgrades to improve forging processes.
  
  

Documentation & Reporting

• Maintain accurate records of forging operations, including process parameters, production data, and quality test results
• Provide regular updates and analysis to management on process improvements and operational issues
• Provide technical support for product documentation creation across factory sites and review produced documentation
• Review qualification and certification development results for special process operators, NDT personnel, and quality inspection personnel, and provide feedback as required.
  
  

Sales Technical Support

• Support the review of manufacturing feasibility for items targeted for sales estimation
• Assist in reviewing and designing production processes for quoted products to meet customer technical requirements
• Participate in technical meetings with engineers when technical support is requested by the sales team
• Fulfil any other responsibilities as required by the company.
  
  

Requirements

Education

• Bachelor's degree in Metallurgical Engineering, Mechanical Engineering, or Materials Science.
  
  

Experience

• Minimum 3 years of proven experience in open-die forging processes within a manufacturing environment
• Strong understanding of hydraulic press operations and metallurgical principles
• Demonstrated experience with large-part open-die forging at 20 tons and above.
  
  

Technical Competencies

• Excellent problem-solving skills with strong attention to detail
• Knowledge of safety regulations and best practices in industrial environments.
  
  

Behavioral Competencies

• Effective communication skills with the ability to collaborate across cross-functional teams
• Strong interpersonal skills and demonstrated ability to work effectively alongside engineers, designers, and other stakeholders
• Ability to perform efficiently in a fast-paced manufacturing environment.