Tool Setter at Orion Castings in Grafton, WI

Position Summary

The HPDC Tooling Setup Technician is responsible for the safe and efficient installation, removal, setup, and changeover of dies and related tooling used in High Pressure Die Casting (HPDC) operations.

This position ensures dies, tooling, cooling systems, hydraulic connections, ejector systems, and related equipment are properly installed and prepared for production. The Tooling Setup Technician works closely with Production, Tooling, Maintenance, Process Engineering, and Quality to minimize changeover time, support successful production startups, and maintain safe and reliable die casting operations.

Essential Duties and Responsibilities

• Perform complete die changes and tooling setups on HPDC machines according to production schedules and established procedures.

• Safely remove dies from die casting machines and install dies required for upcoming production runs.

• Use overhead cranes, hoists, lifting devices, and rigging equipment to safely move and position dies and tooling.

• Verify proper die orientation, positioning, alignment, clamping, and machine interface before startup.

• Install and connect die-related components, including cooling and heating lines, water manifolds, hydraulic lines, core-pull connections, lubrication systems, sensors, switches, and other required connections.

• Connect and verify ejector systems, slides, cores, and other moving tooling components.

• Inspect dies and tooling before installation for visible damage, wear, leaks, loose components, blocked lines, or other conditions that could affect safe operation or production.

• Verify that cooling circuits, water lines, fittings, hoses, seals, and connections are properly installed and free from leaks.

• Install or assist with setup of shot-end components and other tooling-related equipment as required.

• Assist with setup and alignment of trim dies, trim presses, fixtures, and related downstream tooling as required.

• Verify that required die sprays, lubricants, release agents, and tooling supplies are available and properly connected.

• Follow setup sheets, work instructions, tooling specifications, production schedules, and engineering requirements.

• Complete pre-startup inspections and setup verification before releasing equipment for production.

• Support machine startup and first-piece production following die changes.

• Work with Process Engineering and Production to resolve setup-related issues during startup.

• Assist Quality personnel with first-piece or first-article approval as required.

• Troubleshoot basic tooling and setup issues involving alignment, connections, cooling, ejector operation, core pulls, sensors, and related components.

• Immediately identify and communicate damaged or malfunctioning dies and tooling to Tooling, Maintenance, Engineering, or supervision.

• Assist Tool & Die personnel with minor tooling adjustments and repairs when qualified and assigned.

• Maintain dies, setup equipment, rigging equipment, hoses, fittings, clamps, and tooling accessories in clean and serviceable condition.

• Return removed dies and tooling to designated storage or maintenance locations.

• Maintain accurate die-change, setup, inspection, and tooling documentation as required.

• Participate in activities to reduce die-change and setup times and improve equipment availability.

• Support SMED, 5S, continuous improvement, and standardized work initiatives.

• Maintain a clean, organized, and safe work area.

• Follow all company safety, quality, environmental, and operating procedures.

• Perform other related duties as assigned.

Safety Responsibilities

• Follow Lockout/Tagout (LOTO) and stored-energy-control procedures during tooling changes and equipment setup.

• Follow established crane, hoist, rigging, and material-handling procedures.

• Inspect lifting devices and rigging equipment before use as required.

• Never work beneath suspended loads.

• Follow appropriate procedures when working around hot dies, molten metal, hydraulic systems, compressed air, and other hazardous energy sources.

• Wear required personal protective equipment (PPE).

• Immediately report unsafe conditions, damaged lifting equipment, tooling problems, leaks, and other safety concerns.

Required Qualifications

• Previous experience in manufacturing, tooling, machine setup, die casting, mold setup, or a related industrial environment.

• Strong mechanical aptitude and ability to work with large industrial equipment.

• Ability to safely use hand tools, power tools, torque tools, and basic measuring equipment.

• Ability to read and follow setup sheets, work instructions, diagrams, and technical documentation.

• Ability to identify hydraulic, pneumatic, cooling, electrical, and mechanical connections associated with production tooling.

• Ability to troubleshoot basic mechanical and tooling setup problems.

• Ability to work independently and as part of a cross-functional manufacturing team.

• Ability to work assigned shifts, overtime, weekends, and shutdown periods as production requirements dictate.

Preferred Qualifications

• 2+ years of experience performing die changes, mold changes, tooling setup, or similar industrial setup work.

• Previous High Pressure Die Casting experience.

• Experience with aluminum or magnesium die casting operations.

• Experience setting up large HPDC dies and related tooling.

• Experience operating overhead cranes and hoists.

• Experience with industrial rigging and safe lifting practices.

• Knowledge of hydraulic and pneumatic systems.

• Familiarity with die cooling and thermal-control systems.

• Experience with trim presses and trim dies.

• Familiarity with HPDC tooling components, including ejector systems, slides, cores, inserts, cooling circuits, vents, and shot-end components.

• Forklift certification or previous forklift experience.

• Knowledge of Lockout/Tagout procedures.

• Experience with Lean Manufacturing, 5S, and SMED/changeover-reduction principles.

Knowledge, Skills, and Abilities

• Strong mechanical aptitude.

• Knowledge of safe die installation and removal practices.

• Ability to properly select and use lifting and rigging equipment.

• Ability to recognize damaged or unsafe tooling and equipment.

• Strong attention to detail during setup verification.

• Ability to work effectively under production deadlines.

• Good troubleshooting and problem-solving skills.

• Effective communication with Production, Maintenance, Tooling, Engineering, and Quality personnel.

• Dependable attendance and ability to respond to production priorities.

Physical Requirements

• The employee must be able to perform the physical requirements of the position, with or without reasonable accommodation.
• The position regularly requires standing, walking, bending, reaching, climbing, and working around large manufacturing equipment. The employee must be able to safely handle tools and equipment, work around hot surfaces and industrial machinery, and perform work requiring manual dexterity.
• The employee may occasionally be required to lift and/or move up to 50 pounds. Heavier dies, tooling, and components must be moved using approved mechanical lifting equipment.

Work Environment

• Work is performed primarily in a High Pressure Die Casting manufacturing environment. The employee may be exposed to heat, noise, moving machinery, hydraulic equipment, oils and lubricants, metalworking fluids, and other conditions typical of a die casting operation.
• Required PPE must be worn in accordance with company safety policies.

Key Performance Expectations

Successful performance in this position includes:

• Safe and accurate die changes

• Reduction of tooling changeover time

• Correct setup and connection of dies and related equipment

• Minimal setup-related production downtime

• Successful production startups following die changes

• Prevention of tooling and equipment damage

• Compliance with LOTO, rigging, and crane safety requirements

• Accurate completion of setup documentation

• Effective communication with Production, Tooling, Maintenance, Engineering, and Quality