Sr. Process Engineer

POSITION SUMMARY

The Senior Process Engineer will lead and manage casting and metallurgical initiatives that support operations, manufacturing, and product development. This role focuses on implementing and continuously improving processes that safely and cost-effectively meet or exceed customer expectations for quality, consistency, and on-time performance. As the subject-matter expert in metallurgy and casting, the Casting Manager will apply data-driven decision-making and demonstrate intellectual curiosity to solve complex problems and drive innovation.

This position collaborates cross-functionally with Manufacturing, Engineering, Supply Chain, and Quality teams, and works directly with shop-floor personnel to implement solutions. The role also involves external engagement with customers and vendors, adhering to confidentiality and non-disclosure protocols.

ESSENTIAL RESPONSIBILITIES

Demonstrates company values and shares the organizational commitment to safety, quality, productivity, and a high-performance workforce through positive employee relations.

Safety:

• Ensure personal and team compliance with internal policies and external safety, environmental, and health regulations.
• Collaborate with EHS Manager to ensure safety-first process and equipment changes.
• Participate in safety observations and incident investigations.
• Promote a safety-first culture across all operations.

Operations:

• Oversee bimetallic casting activities including product recipes, testing, NDE, and subcontracted processes.
• Optimize casting process variables such as heat-up time, spin rate/G-forces, mold preheat, melt quality, and inlay bonding.
• Align product and testing priorities with furnace production schedules.
• Maximize casting material utilization while maintaining product integrity.
• Monitor furnace performance and coordinate maintenance and upgrades.
• Ensure complete and accurate documentation of casting records and shop orders.
• Manage process specifications and training requirements.
• Serve as the business expert in materials and additive manufacturing across all locations.
• Stay current with state-of-the-art casting technologies and maintain casting as a core competency.

Process/Product Development & Improvement:

• Lead product development initiatives, including new inlay/matrix formulations for barrels.
• Apply structured problem-solving tools such as DOE, 5 Whys, FMEA, and Six Sigma to drive improvements.
• Utilize thermal modeling and simulation techniques to optimize casting processes.
• Implement plans to improve product quality and consistency.
• Ensure compliance with quality systems and procedures.
• Investigate customer claims and internal CARs; lead root-cause analysis and corrective actions.
• Develop and report metrics using tools like SPC, SQC, and Lean methodologies.

Customer Satisfaction Support:

• Participate in Specific Product Design (SPD) processes to meet customer expectations.
• Review test results for compliance with specifications.
• Lead defect reduction initiatives targeting porosity, lumpiness, and cracking.
• Resolve customer complaints through direct engagement and technical analysis.

General Responsibilities:

• Perform other duties as needed to support company objectives.
• Maintain on-site presence to foster strong relationships and team collaboration.
• Travel (10–20%, including international) to support customer and operational needs.

Requirements

Work Experience Required:

• Minimum 5 years in a managerial or leadership role within centrifugal casting metallurgy, with hands-on shop-floor experience.
• Proven success managing complex projects in product and process development.

Education and Skills:

• Bachelor’s degree in Materials Science, Mechanical Engineering, Metallurgical Engineering, or related field.
• Strong background in materials or mechanical engineering.
• Deep understanding of casting process variables and defect mechanisms.
• Hands-on experience with centrifugal or high-performance casting.
• Exposure to thermal modeling, melt shop operations, and inlay bonding techniques.
• Data-Driven: Makes decisions based on evidence and metrics
• Analytical & Decisive: Solves complex problems and takes timely action
• Hands-On: Present and engaged in operations, leads by example
• Poised: Maintains professionalism and calm under pressure
• Track record of reducing scrap, rework, and warranty claims
• High Initiative: Proactively identifies opportunities and drives outcomes
• Results-Driven: Delivers measurable, high-impact business results
• Intellectually Curious: Seeks new ideas and challenges the status quo
• Team Oriented: Strong ability to collaborate effectively with cross-functional teams to identify challenges, develop innovative solutions, and drive successful implementation
• Highly functional with ERP (Microsoft AX Dynamics, preferred) and HRI systems Strong computer skills including MS Office products, such as Outlook, Word, Excel, PowerPoint, Power BI, Access, Project, etc.