Die Casting Maintenance Technician - Casting

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Job Summary

The Die Casting Maintenance Technician is responsible for maintaining the reliability, availability, and performance of High Pressure Die Casting (HPDC) production equipment and auxiliary systems. This position performs preventive, predictive, and corrective maintenance activities to ensure safe operation, maximize equipment uptime, improve Overall Equipment Effectiveness (OEE), and support the production of quality castings. The technician works closely with Production, Tooling, Process, Engineering, Quality, and Manufacturing Engineering to support continuous improvement initiatives and minimize equipment downtime.

Essential Duties and Responsibilities

· Perform preventive, predictive, and corrective maintenance on HPDC machines, trim presses, furnaces, dosing systems, ladles, shot-end systems, hydraulic and pneumatic equipment, cooling systems, vacuum systems, lubrication systems, and auxiliary equipment.

· Troubleshoot mechanical, hydraulic, pneumatic, electrical, and automation failures to restore equipment safely and efficiently.

· Inspect, repair, replace, and adjust machine components to maintain equipment performance and production capability.

· Perform machine alignments, calibrations, functional testing, and equipment verification following maintenance activities.

· Support equipment installations, commissioning, relocations, and production start-ups.

· Support die changeovers, die setup verification, and production start-up activities to achieve optimal process performance.

· Support robotic systems, automated spray equipment, extractors, conveyors, and material handling equipment.

· Assist in troubleshooting PLC-controlled equipment, sensors, actuators, safety devices, and automated production systems.

· Monitor equipment performance and identify opportunities to improve reliability, cycle time, machine availability, and process stability.

· Support implementation of engineering changes, equipment upgrades, and automation improvements.

· Execute preventive and predictive maintenance programs in accordance with maintenance schedules, OEM recommendations, and reliability standards.

· Complete inspections, lubrication, condition monitoring, and equipment health assessments.

· Participate in root cause analysis (RCA), failure analysis, and corrective action implementation to eliminate recurring equipment failures.

· Recommend improvements that increase equipment reliability, reduce maintenance costs, and improve Overall Equipment Effectiveness (OEE).

· Accurately document maintenance activities, work orders, downtime events, failure causes, corrective actions, and spare parts usage within the Computerized Maintenance Management System (CMMS).

· Maintain maintenance records and support equipment history tracking.

· Assist with spare parts identification, inventory control, and critical spare management.

· Participate in TPM, Lean Manufacturing, 5S, Kaizen, and continuous improvement initiatives.

· Follow all company safety policies, environmental regulations, Lockout/Tagout (LOTO) procedures, and PPE requirements.

· Maintain a clean and organized work area in accordance with 5S standards.

· Ensure all repairs and maintenance activities comply with quality, environmental, and safety requirements.

· Communicate effectively with Production, Engineering, Tooling, and Maintenance personnel during shift handoffs and downtime events.

· Perform other duties as assigned in support of plant operations.

Required Qualifications

· High school diploma or GED required; technical diploma, apprenticeship, or certification in industrial maintenance, mechatronics, electrical, machining, tool and die, or a related field preferred.

· Minimum of 2 years of maintenance experience in a manufacturing environment; experience in automotive, die casting, foundry, machining, or metal forming operations preferred.

· Working knowledge of mechanical systems, hydraulics, pneumatics, electrical controls, motors, sensors, bearings, gearboxes, pumps, and industrial automation.

· Ability to troubleshoot equipment issues safely and efficiently with minimal supervision.

· Ability to read and interpret technical drawings, electrical schematics, hydraulic and pneumatic diagrams, and equipment manuals.

· Experience using precision measuring tools such as calipers, micrometers, indicators, and gauges preferred.

· Basic computer skills and ability to enter maintenance records, work orders, and parts information into a computerized maintenance management system.

· Ability to work overtime, weekends, shutdowns, and flexible shift schedules as business needs require.

Preferred Qualifications

· Experience maintaining high-pressure die casting equipment and related auxiliary systems.

· Experience with PLC troubleshooting, robotics, automation, machine guarding, furnaces, molten metal handling systems, trim presses, and die spray systems.

· Welding, fabrication, machining, or toolroom experience.

· Forklift, crane, hoist, aerial lift, or rigging experience.

· Knowledge of lean manufacturing, 5S, root cause analysis, and continuous improvement methods.

Knowledge, Skills, and Abilities

· Strong understanding of High Pressure Die Casting (HPDC) processes.

· Working knowledge of HPDC machine components including hydraulic power units, vacuum systems, lubrication systems, and die temperature control equipment.

· Experience maintaining auxiliary equipment such as melting and holding furnaces, dosing furnaces, molten metal transfer systems, die spray systems, trim presses, quench systems, cooling towers, water manifolds, and compressed air systems.

· Ability to troubleshoot casting process issues related to equipment performance

· Understanding of thermal management principles, including temperature control, cooling circuits, thermal balance, heat transfer, and water flow optimization.

· Knowledge of hydraulic systems, proportional valves, servo valves, accumulators, pressure regulation, hydraulic schematics, and troubleshooting techniques.

· Strong knowledge of pneumatic systems, vacuum circuits, valve manifolds, regulators, actuators, and compressed air distribution systems.

· Ability to troubleshoot industrial electrical systems including motors, VFDs, sensors, proximity switches, encoders, relays, safety circuits, and control panels.

· Basic understanding of PLC troubleshooting, including interpretation of ladder logic, I/O diagnostics, alarms, HMI interfaces, and communication with controls engineers.

· Experience supporting industrial robots used for part extraction, die spraying, insert loading, and automated material handling.

· Ability to inspect and maintain die components including slides, cores, ejector systems, guide pins, bushings, cooling lines, vents, vacuum ports, shot sleeves, plungers, and die protection systems.

· Knowledge of predictive maintenance techniques including vibration analysis, thermography, oil analysis, ultrasonic inspection, and condition monitoring.

· Ability to read and interpret hydraulic, pneumatic, electrical, mechanical, and process schematics, equipment manuals, and OEM documentation.

· Experience using precision measuring instruments including calipers, micrometers, dial indicators, bore gauges, height gauges, and alignment tools.

· Familiarity with Computerized Maintenance Management Systems (CMMS) for work order management, preventive maintenance scheduling, spare parts control, and equipment history.

· Understanding of Overall Equipment Effectiveness (OEE), Mean Time Between Failure (MTBF), Mean Time to Repair (MTTR), Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), Total Productive Maintenance (TPM), Lean Manufacturing, and 5S principles.

· Strong understanding of Lockout/Tagout (LOTO), machine guarding, arc flash awareness, confined space requirements, and safe work practices associated with molten aluminum operations.

· Ability to identify opportunities to improve equipment reliability, process capability, cycle time, die life, energy efficiency, and maintenance effectiveness through continuous improvement initiatives.

Physical Requirements and Work Environment

· Ability to stand, walk, climb, bend, kneel, squat, reach, push, pull, and work in confined spaces or at elevated heights.

· Ability to lift up to 50 pounds with or without reasonable accommodation.

· Ability to work in a manufacturing environment with exposure to molten aluminum, high temperatures, moving machinery, hydraulic systems, industrial noise, dust, lubricants, and chemicals while wearing required PPE.

· Ability to safely perform maintenance activities using Lockout/Tagout procedures and other established safety practices.

Schedule and Reporting

This position may be assigned to off shifts based on business needs. Overtime, shutdown coverage, and emergency call-in support may be required. The position typically reports to the Maintenance Supervisor, Maintenance Manager, or designated plant leadership.

Work Authorization

Applicants must be legally authorized to work in the United States at the time of hire. Candidates who currently hold valid work authorization under a TN or H-1B visa may be considered, provided they are authorized to work for this employer without requiring new or additional visa sponsorship. The company is unable to sponsor new employment-based visas or other immigration sponsorship for this position.

Equal Employment Opportunity

The company is an Equal Opportunity Employer and considers qualified applicants without regard to race, color, religion, sex, national origin, disability, veteran status, age, genetic information, or any other status protected by applicable law.

Awareness, Unity, Empowerment:

At Magna, we believe that a diverse workforce is critical to our success. That’s why we are proud to be an equal opportunity employer. We hire on the basis of experience and qualifications, and in consideration of job requirements, regardless of, in particular, color, ancestry, religion, gender, origin, sexual orientation, age, citizenship, marital status, disability or gender identity. Magna takes the privacy of your personal information seriously. We discourage you from sending applications via email or traditional mail to comply with GDPR requirements and your local Data Privacy Law.

AI-Assisted Screening Disclosure

As part of our commitment to a fair, consistent, and efficient recruitment process, we may use artificial intelligence (AI) tools to assist in the initial screening of applications submitted through our Workday system. These tools help identify qualifications and experience that align with the role requirements. Please note that AI is used solely to support our recruiters. Final decisions are always made by the hiring manager and the hiring team. Importantly, no applicant data is shared externally through these AI tools. All information remains securely within our systems and is handled in accordance with our privacy and data protection policies.

Under conditions defined by applicable law, you may have the right to request an explanation of how AI is used to support decision-making.

If you have any questions or concerns about this process, feel free to contact our Talent Attraction team.