Formability Technician

Long Description

JOB SUMMARY

The formability specialist is responsible for monitoring, analyzing and improving formability performance in cold stamping operations. This position supports production, die engineering, tooling, and quality teams to prevent forming failures, reduce scrap, optimize material utilization, and ensure robust die performance during the current production and new program launches.

DUTIES AND RESPONSIBILITIES

• Production Monitoring & Risk Control
• Monitor high-risk parts during production runs.
• Perform first and last piece inspections on critical components.
• Conduct circle grid analysis (CGA) on designated parts and maintain master panels.
• Measure and track thinning percentages in known failure zones.
• Maintain and update forming performance tracking database.
• Coordinate with scheduling to support high-risk production runs.
• Support off-shift production as required for critical components.
• Conduct root cause analysis for splits, wrinkles, necking, and excessive thinning.
• Correlate material mechanical properties (YS, UTS, n-value, r-value) with forming performance.
• Track and analyze steel YTE and n-values for high-risk components.
• Evaluate material flow restrictions, draw bead function, and binder performance (draw die map).
• Develop together tooling a corrective action plans to prevent recurring forming failures.
• Recommend die modifications to improve forming robustness.
• Support die tryouts and engineering change implementation.
• Participate in new program launches from a formability perspective.
• Review and validate forming simulation results.
• Validate material changes prior to production release.
• Support any documentation related to forming risk and material performance.
• Work closely with Die Engineering and tooling team to track process improvements.
• Identify scrap reduction and material utilization improvement opportunities.
• Develop and standardize circle grid and thinning analysis best practices.
• Train production and quality personnel on forming risk indicators.
• Lead initiatives to improve forming process stability and die repeatability.
• Implement data-driven monitoring systems using Excel or other tracking tools.

EDUCATION AND EXPERIENCE

1.    Associate’s or Technical Degree in Manufacturing or equivalent experience in stamping / formability (minimum 3 years). 
2.    Minimum 3–5 years of experience in automotive stamping environment.
3.    Experience with draw dies and material flow analysis (preferred).

4.    Experience performing circle grid analysis and thinning measurements (preferred).

5.    Experience in quality inspection and forming defect evaluation.

KNOWLEDGE, SKILLS AND ABILITIES

1.    Strong understanding of cold stamping and draw die function.
2.    Knowledge of Forming Limit Curves (FLC) and FLD interpretation (preferred)
3.    Root Cause Analysis methodology (5 why’s)
4.    GD&T interpretation.
5.    Understanding of lubrication impact in forming processes (preferred).

PHYSICAL AND MENTAL REQUIREMENTS OF THE POSITION

1.    Ability to stand, walk, and move throughout production areas for extended periods.
2.    Ability to lift up to 50 pounds occasionally.
3.    Exposure to manufacturing environment including moderate noise levels.
4.    Specific vision abilities required: close vision, distance vision, color vision, depth perception, and focus adjustment.
5.    Ability to concentrate on technical analysis tasks for extended periods.
6.    Ability to clearly communicate technical findings verbally and in writing.