Description
The Staff Tooling Engineer is responsible for leading and optimizing tooling development from initial tooling design through mass production sustaining with ODMs and CMs. This role plays a critical part in ensuring that tooling design meets strict quality, throughput, and cost targets while driving Design for Manufacturing (DFM) and Design for Assembly (DFA) in close collaboration with internal Mechanical Engineering, Quality, and Supply Chain teams.
Key Responsibilities:
- Collaborate with cross-functional engineering teams to conduct robust DFM/DFA reviews, guiding process selection, material selection, and tooling qualification plans.
- Lead technical reviews for tooling designs, mold layouts, and drawings, including Moldflow simulation, gate placement, cooling, parting lines, and ejector pin layouts.
- Validate tooling designs with suppliers and toolmakers to proactively troubleshoot issues.
- Drive tooling deliverables across all Hardware Product Development phases to support key NPI programs, ensuring timely OK2TOOL and OK2FAB approvals.
- Work closely with ODMs and CMs to manage tooling build progress, trial runs, root cause troubleshooting, and yield improvements on the manufacturing floor.
- Establish and maintain supplier-facing tooling maintenance standards and asset management procedures.
- Conduct on-site supplier and tooling audits to ensure quality maintenance and mold longevity.
- Partner with Quality and Supplier Quality Engineering teams to establish SOPs for part inspection, technical support for PPAP, and dimensional/cosmetic qualification.
- Assist in building simulation models for tooling and part cost analysis, evaluating factory capacity/capability, and driving continuous improvement initiatives for tooling cost reduction and cycle time optimization.
Requirements:
- Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Tooling Engineering, or equivalent practical experience.
- 8+ years of hands-on engineering experience in plastic injection molding, die casting, sheet metal stamping/bending, and tooling fabrication within a high-volume manufacturing environment.
- In-depth knowledge of tool design, tool steel selection, mold/die fabrication, heat treatment, and post-processing.
- Proficiency in 3D CAD modeling and simulation software.
- Strong familiarity with DFM/DFA principles, GD&T, engineering drawings, and quality management frameworks.
- Strong analytical and root cause analysis skills.
- Excellent written and oral English communication skills for effective collaboration with cross-functional global teams and international suppliers.
- Ability to travel up to 30% to manufacturing facilities and supplier locations as needed.