DescriptionTuwaiq 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 ResponsibilitiesTechnical 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.
RequirementsEducation
- 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.
