Tooling Design Section Head
INCOM Egypt
Total years of experience :11 years, 2 Months
My job responsibilities are including the following:
*Design of plastic injection molds and develop existing ones .
* Design and maintenance of progressive sheet metal dies and develop existing
ones.
* Planning and management of all manufacturing processes produced by the CNC
workshop for making molds, dies, tooling elements and spare parts that used in
production of electric wires, power cables and Harnesses.
* Development the existing crimping tools (used in Harnesses manufacturing) in
order to increasing its life time, efficiency, availability, ease of storing and selecting.
* Development of the maintenance procedures for existing plastic mols and sheet
metal dies, applicators, and crimping tools.
* Development of CNC tooling manufacturing workshop operations by increasing
its productivity and efficiency for persons and machines, this operations including
advanced operations such as 4 axis CNC Vertical Milling machining, EDM wire cut,
EDM spark erosion (Z machine), this development processes includ searching and
providing the workshop with new tooling and materials, optimization of
machining operations and programs, increasing productivity and efficiency of
technicians by training and motivation.
* Researching for tooling vendors (locally or internationally) of all needed tools and
elements required for tooling workshop, injection molds, sheet metal dies and
crimping tools.
My job duties is concluded in :
1- The development of the company capabilities for design and manufacturing - In house- plastic injection molds and sheet metal progressive dies for plastic and copper elements that involved in the production of automotive wiring harnesses, The design of this molds and Dies is according to standard mold basis and fulfills all requirements of manufacturing heavy production injection molds, which required special tool steels such as M303, M238, W302, K110, K100, C45, and special design method )Quick Changing Inserts for example).
2- Supervision and following of all manufacturing and assembly processes for mold and Dies parts .
3- Responsible for Outdoor Manufacturing operations for molds and dies parts that will be made out doors which include Spark and Wire Cut EDM operations, and I was responsible for preparation of all Technical Drawings and CAM files (Such as DXF Files) and 3 D Moldels (Such as EDM Electrodes) for all outsourcing operations.
4- Programming of CNC machines by SolidCAM, and I was responsible for searching and providing the CNC Department with Tooling Resources and suppliers .
5- Responsible for Purchasing Orders for molds and Dies Row Materials and its required accessories.
-Design :
1- Product design and improvement for components of light current wiring modules (On- Off Switches-Sockets- Plugs- Hubs and other wiring components) which include plastic and sheet metal parts using solid works software.
2- Mechanical design for heavy production Plastic injection molds according standard specifications that are required for the company products using Solidworks, PowerShap softwares.
-Machining :
1- Supervision of all manufacturing processes of mold components that include CNC Milling, Spark EDM, WireCut EDM, Grinding and Polishing.
2- Responsible for programming of CNC machine tools Using CAD_CAM softwares-EDGECAM and Power Mill - such as:
- Vertical Milling machines (3 axis).
- Wirecut EDM machines using Solidworks.
3- Responsible for SPARK EDM Electrode Design and the preparation of its required programming sheets and workshop drawings.
4- Supervision of the assembly processes of the mold
tool.
-Maintenance :
-Supervision of maintenance and repair works for mold tools.
Documentation :
-Prepare the technical manuals for new products.
• Using reveres engineering to remanufacturing custom products and Spare Parts.
• Design and machining all kinds of plastics moulds (injection moulds, blow moulds, vacuum moulds) , Sheet metal dies, Spare Parts using Solidworks and Autocad,
• Selection of the materials for machined products, mould tools, and cutting tools according standard specifications.
• Prepare all Required machining Processes Sheets
• Selection of the suitable manufacturing processes (Machining Processes) according to the customer requirements.
• Programming of CNC milling machines and routers via edgecam.
• Programming of CNC wire cut machines and Laser CNC machines using Autocad.
• Responsible for the technical support and training of solidworks design issues for the work partners in the company.
1. Prepare the production plane for the monthly production demands
2. Control the daily production processes of Cast Iron according to the production plane which includes:
a- Sand mold making processes that include control the required quantities of sand mixture according to its standard composition.
b- Melting metals processes that include control of the required quantities of the charges that needed to be molten in the electrical induction furnaces- from warehouse to the furnaces - according to the standard composition of the cast iron.
Fields of production Engineering : 1- Design of machine tools elements 2- Manufacturing Engineering 3- Industrial Engineering