Foundry Processing Engineer

Wellman Dynamics Division•Creston, IA

33d•Onsite

About The Position

The Foundry Processing Engineer performs a variety of engineering assignments focused on developing and implementing production and processing methods and controls to ensure quality standards are met in the most cost-efficient manner. This role involves investigating and resolving work-in-process problems, reviewing standard, general, and special processes for improvement and compliance, and recommending and implementing modifications in operations sequences. The engineer will monitor assigned operations to ensure adherence to approved methods and quality standards. A key aspect of this position is close collaboration with Production, Engineering, and Quality teams. The engineer will also be responsible for developing and refining casting methods to enhance quality, yield, and throughput, analyzing production data to maintain process specifications, reduce scrap, and ensure ISO quality standard compliance. Technical issues during melting, molding, heat treating, and finishing must be resolved, and accurate, up-to-date work instructions and process change records maintained. The role includes leading lean manufacturing projects, material optimization, and energy reduction initiatives, as well as coordinating with maintenance for equipment optimization and tooling adjustments. Further responsibilities include reviewing and updating manufacturing processes for consistent output and quality, designing and processing development samples and trials, interpreting inspection results, investigating nonconforming materials, and instituting corrective actions. The engineer will also create and maintain process work instructions, recommend and implement new materials, processes, and equipment, and work with other departments to identify root causes of discrepant material and develop corrective actions. Familiarity with customer and regulatory specifications, as well as internal work instructions and ISO practices, is required.

Requirements

Bachelor’s degree or Technical Degree in Mechanical Engineer or Metallurgical Engineer or related field (Minimum of 2 years’ experience will be considered in lieu of education requirement).
Previous experience in a foundry or industrial manufacturing environment.
Understanding of metal castings, specifically aluminum and magnesium, techniques, metal alloys, and solidification.
Proficient at SolidWorks or casting simulation software.
Strong problem-solving skills and ability to work with cross functional teams.

Responsibilities

Perform a variety of engineering assignments in developing and implementing production/processing methods and controls to meet quality standards in the most cost-efficient manner.
Investigate and resolve work-in-process problems.
Review standard/general and special processes for improvement and compliance.
Recommend and implement improvements and/or modifications in sequence of operations, and related matters.
Monitor assigned operations to ensure compliance with approved methods and quality standards.
Work closely with Production, Engineering, and Quality.
Develop and refine casting methods to improve quality, yield, and throughput.
Analyze production data to keep processes within specifications, reducing scrap, and entering ISO quality standard compliance.
Resolve technical issues during melting, molding, heat treating, and finishing.
Maintain accurate, up-to-date work instructions and process change records.
Lead lean manufacturing projects, material optimization, and energy reduction initiatives.
Coordinate with maintenance to optimize equipment performance and assist with tooling adjustments.
Review manufacturing processes for improvement to provide consistent output and quality of manufacturing materials and methods.
Update and maintain manufacturing processes to ensure manufacturing materials are within manufacturing specifications using robust methods.
Design and determine development samples and trials, process and review through all manufacturing, inspection, and inspection departments.
Interpret inspection results, investigate nonconforming materials, and institute corrective action, sample and confirm corrective measures, document, and amend process procedures.
Investigate and resolve production process problems.
Create, document and maintain process work instructions for all casting process areas.
Recommend trial and implement new materials, processes and equipment to improve efficiency and quality.
Work with Product Engineering, Quality and Manufacturing to identify root cause of discrepant material and assist in developing corrective action.
Be familiar with customer and regulatory specifications.
Be familiar with all internal work instructions and forms, and maintain good ISO practices.