QUALIFICATIONS:

EDUCATION: Bachelor’s degree or Technical Degree in one of the following fields Mechanical Engineer or Metallurgical Engineer or related field. Minimum of 5 years’ experience will be considered in lieu of education requirement.

EXPERIENCE: Minimum 5 years Engineering experience in aluminum and/or magnesium sand casting foundry. Minimum of 5 years managerial experience and manufacturing experience. Strong leadership and organizational skills, Team oriented. Metallurgical background a plus.

GENERAL DESCRIPTION:

Leads production problem solving activity in conjunction with the Quality, Product Engineering, and Manufacturing operations with the focus on reducing waste and cost while improving OTD. Facilitates agreement on action plans to improve gating systems and/or process improvements to foundry processes to reduce product variability. Performs a variety of engineering assignments in developing and implementing production/processing methods and controls to meet quality standards in the most cost-efficient manner. Investigates and resolves work-in-process problems, review standard/general and special processes for improvement and compliance. Recommends and implements improvements and/or modifications in sequence of operations, and related matters. Monitors assigned operations to ensure compliance with approved methods and quality standards. This position will require working closely with Production, Engineering, and Quality.

SPECIFIC DUTIES:

• Drive step-change improvements in casting, solidification, sand casting production, and defect reduction to improve yield.
• Develop, troubleshoot, and refine sand casting techniques, molding, melting, pouring, for maximum quality and yield.
• Lead a team of engineers and technical support for manufacturing operations, including setting clear expectations and monitoring them.
• Direct manufacturing engineering staff, providing technical expertise in tooling design, pattern making, and sand management.
• Ensure all foundry processes comply with safety standards, environmental regulations, and quality management systems.
• Oversee design, procurement, installation, and maintenance of machinery, tooling, and automation.
• Oversee advanced quality planning, tooling, procurement, and pilot runs for new casting designs.
• Ensure adherence to metallurgical standards and safety regulations, fostering a “right-time-first” culture.
• Manage departmental budgets and project timelines.
• Utilize Lean methodologies and 8D/RCCA to reduce waste, reduce cost of non-quality, and improve productivity.
• Six Sigma certified with demonstrated results.
• Proficiency in CAD tools, 3D modeling, GD&T, and simulation software.
• Expert in root cause analysis and technical problem solving.
• Responsible for ensuring builds are made following the work instructions and technical specifications consistently.
• Provide technical solutions to a variety of complex build process steps for each casting.
• Strong knowledge of sand-casting materials, solidification, gating/risering design, and simulation software.
• Support new product introduction through DFM reviews, PFMEA and process planning.
• Present company information at technical presentations, concurrent engineering team member.
• Research and develop new or existing process or systems to maintain and improve company’s competitive spanet position.
• Sustain MRB log and Initiate follow-up and investigation to ensure action is taken.
• Work with Product Engineering and Quality Engineering to resolve metallurgical issues with production castings and ensure team complete correction actions.
• Strong leadership and mentoring skills.
• Strong communication and interpersonal abilities to bridge engineering, quality, and manufacturing while supporting the customer’s needs.
• Leads Melt Manager, Foundry, CNC Engineer, CNC Engineer Technicians, Metallurgist, Engineering Materials Technician in cost reduction, waste reduction, and increased throughput.
• High level of collaboration and report with Product Engineering and Quality Engineering.
• Oversee CNC and degating activities.
• Standardize fixture manufacturing.
• Standardize fixture to machine interface.
• Rigorous cutting tool management system, tool setting, pot/tool management.
• Writing M-Code, G-Code to minimize cutting efficiency.
• Achieve zero damaged parts from CNC cuts.
• Reduce labor in rotary file vs. CNC run cost.
• Written standards for operators on shift/ day/weekly PM.

These job duties are not all inclusive. The Company, from time to time, may require the incumbent to perform additional duties as assigned.