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