Senior Metallurgical Engineer

The Senior Metallurgical Engineer will provide technical leadership for the gray and ductile iron green sand foundry. This position combines metallurgical expertise with significant manufacturing process engineering responsibilities to improve foundry performance, optimize manufacturing processes, enhance product quality, and support continuous improvement initiatives.

Responsibilities

• Provide technical leadership for gray and ductile iron melt chemistry, metallurgical properties, and manufacturing processes throughout the foundry.
• Lead manufacturing process improvement initiatives to optimize casting quality, improve productivity, reduce scrap, minimize manufacturing variation, and improve operational efficiency.
• Monitor and improve green sand systems and overall foundry process performance.
• Analyze casting defects, determine root causes, and implement sustainable corrective actions.
• Identify, lead, and implement continuous improvement projects focused on quality, productivity, cost reduction, efficiency, and process optimization.
• Monitor production data, manufacturing trends, and quality metrics to identify opportunities for improvement.
• Maintain chemical and mechanical certification programs.
• Support pattern layouts, tooling improvements, and process development for new and existing products.
• Update manufacturing routings, bills of material, and process documentation to reflect process improvements.
• Evaluate and implement new technologies related to foundry process control, metallurgy, and manufacturing improvements.
• Partner closely with Operations, Engineering, Maintenance, Production, and Quality teams to resolve technical manufacturing issues and improve plant performance.
• Supervise, coach, train, and develop Foundry Laboratory Technicians, including scheduling, performance management, and daily technical support.
• Provide metallurgical and technical training for supervisors, technicians, and production personnel.
• Support customer quality investigations and corrective action activities.
• Drive initiatives to improve Cost of Quality, reduce PPM, and increase customer satisfaction.
• Ensure compliance with ISO 9001 quality standards and internal quality management systems.

Qualifications

• Bachelor's degree in Metallurgy, Materials Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical field, or equivalent foundry experience.
• 3+ years of experience in a gray and/or ductile iron green sand foundry.
• Strong knowledge of metallurgy, melt practices, iron chemistry, foundry operations, and manufacturing process improvement.