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. Show more Show less

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