Bahadir Tavusbay
Injection Molding § Tooling Engineer (HPDC)
Istanbul
Summary
Dynamic and detail-oriented HPDC Tooling & Casting Engineer with over 4 years of hands-on experience in die casting, CNC machining, and project management. Proficient in advanced CAD software (CATIA V5, Solidworks, Cimatron), prototype tooling methods, and material science. Proven track record of implementing lean manufacturing principles, managing capital projects, and providing exceptional technical customer service. Adept at using analytical tools for performance optimization and cost reduction
Overview
7
7
years of professional experience
3
3
Certifications
Work History
Senior (HPDC) Die Casting & Tooling Engineer
Ugur Metal Aluminum Die Casting
2 2021 - Current
- Experience with 3&4 axis cnc machines
- Specialist in HPDC manufacturing technique and related processes such as: machining, welding, polishing, mold designing, composite layup and assembly
- Enhanced tooling efficiency by designing, developing, and implementing new tooling systems.
- Worked 3 year at tooling department and knowledge about production of die casting tools, mold bases, die sets, plates, bars and related components
- Responsible for continuous process flow also Layout working, production area improvement studies (FMEA, DFMEA, Lean manufacturing etc.)
- Created detailed technical drawings of designed tools using CAD software to facilitate accurate fabrication.
- Increased machine uptime by maintaining and repairing tools, dies, jigs, fixtures, and molds.
- Adaptation of new projects to the foundry; starting from mould design to sample production
- Implemented preventive maintenance programs to reduce downtime caused by unexpected equipment failures.
- Cost saving improvements of consumable materials (worked as a buyer for 9 months, find out new global suppliers for cutting tools, mold making components and high performance steels for molds)
- Performance improvement of cutting tools in Tooling house with World class suppliers (ball mills, end mills, drills and bushers)
- Resolved technical and quality issues by collaborating with customer, manufacturing, quality assurance, vendors and supplier personnel.
- Worked closely with suppliers to ensure timely delivery of high-quality materials while minimizing costs associated with inventory management.
- Engaging in Blue Collar recruitment processes and advising human resources.
- Coordinated training programs for new employees on proper handling, use, and maintenance of tools.
HPDC Project Engineer
Ugur Metal Aluminum Die Casting
04.2019 - 02.2021
- Responsible for Industrial Engineering & Support of new casting development applications into mass production
- Provided technical expertise throughout all phases of the project, ensuring accurate execution of designs and specifications.
- Implementation of 3 robotic die casting cells with StrikoVestofen / Krown furnaces, Kuka robots, 2 axis automated sprays Wollin and Acheson with trim presses
- Complete implement of programming KUKA robot for part extraction from HPDC machines, cooling and putting the part to trimming press
- Analyzing the performance losses of high pressure die casting cells
- Energy consumption improvements of production lines melting (dosing furnaces)
- Digitalization pilot of foundry (Implementation of new production tracking system and its connection with ERP system)
- Managed projects effectively to deliver finished work on time
- Calculated risks during project development and managed risks throughout projects
- Spearheaded 214 HPDC projects through project planning and design
- Controlled engineering activities to maintain work standards, adhere to timelines and meet quality assurance targets
Project Staff
Arçelik Global A.Ş
05.2017 - 09.2017
- Prepared project proposals, including cost estimates, schedules and project specifications.
Education
MicroMasters Program: Fundamentals of Manufacturing Processes and Principles of Manufacturing -
Massachusetts Institute of Technology
Boston, US 2 2023 - 8 2024
Bachelor of Science: Manufacturing Systems and Industrial Engineering - undefined
Sabanci University - Istanbul
09.2013 - 12 2017
High School Diploma - undefined
French High School Sainte-Pulcherie - Istanbul
09.2008 - 6 2013
undefined
04.2012 - 6 2012
Skills
Tooling design
CNC Programming
CAD and CAM proficiency
Fixture design
Lean manufacturing principles
Computer-Aided Engineering
Robotics Integration
Injection molding expertise
5S organization
Problem-solving abilities
Certification
- 11/01/20, IELTS (6,5)
- 06/01/13, Diplôme études en langue française DELF B2
- 07/01/19, MSA (Measurement System Analysis) T
Timeline
HPDC Project Engineer
Ugur Metal Aluminum Die Casting
04.2019 - 02.2021
Project Staff
Arçelik Global A.Ş
05.2017 - 09.2017
Bachelor of Science: Manufacturing Systems and Industrial Engineering - undefined
Sabanci University - Istanbul
09.2013 - 12 2017
undefined
04.2012 - 6 2012
High School Diploma - undefined
French High School Sainte-Pulcherie - Istanbul
09.2008 - 6 2013
Senior (HPDC) Die Casting & Tooling Engineer
Ugur Metal Aluminum Die Casting
2 2021 - Current
MicroMasters Program: Fundamentals of Manufacturing Processes and Principles of Manufacturing -
Massachusetts Institute of Technology
2 2023 - 8 2024
- 11/01/20, IELTS (6,5)
- 06/01/13, Diplôme études en langue française DELF B2
- 07/01/19, MSA (Measurement System Analysis) T
VNORD04/01/19, FMEA (Failure Mode and Effect Analysis) T
VNORD
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