Forging Process Engineer

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.