Manufacturing Engineer - Lost Foam

Brunswick Corporation•Fond du Lac, WI

2d•$62,800 - $90,500•Onsite

About The Position

The Manufacturing Engineer - Lost Foam will provide hands-on engineering support and technical ownership for a defined family of castings at Mercury’s aluminum lost foam foundry, covering the process from foam pattern production through finished cast parts. The role works directly on the shop floor to improve processes, resolve production challenges, and support safe, stable production and high-quality castings. The engineer partners with operators and cross-functional teams in foam molding, tooling, quality, maintenance, controls, machining, finishing, and other areas. The position supports production and new casting program launches, evaluates manufacturing data and process parameters, and contributes to process improvements across the lost foam value stream. The position is onsite at Plant 17 in Fond du Lac, Wisconsin, and works in a foundry environment. Travel is not required. The hiring range is $62,800–$90,500 annually, and the position is eligible for an annual discretionary bonus.

Requirements

Bachelor’s degree in Manufacturing, Mechanical, Industrial, or Metallurgical Engineering, or equivalent.
Up to five years of manufacturing, engineering, foundry, or related experience.
Demonstrated communication and interpersonal skills and the ability to work effectively with cross-functional teams.
Proficiency with Microsoft 365, including Excel, Teams, SharePoint, and Planner.

Nice To Haves

Coursework related to metal casting, lost foam, sand molding, foundry processes, or manufacturing engineering.
Experience with PLCs, industrial controls, Allen-Bradley systems, ABB robotics, Ignition, SQL, Power BI, process traceability, shop-floor dashboards, data collection systems, or advanced inspection technologies.
Experience with 3D CAD software and the ability to review part, pattern, tooling, and manufacturing designs.
Familiarity with Lean Manufacturing, Six Sigma, statistical process control, or structured problem-solving methods.
Strong analytical and problem-solving skills, including the ability to use data and sound engineering judgment to make decisions.
Ability to deliver results independently and as part of a cross-functional team.
Demonstrated project management skills and the ability to manage multiple priorities.
Team-oriented mindset, ability to learn quickly, and ability to thrive in a foundry environment.
Ability to work in a fast-paced, constantly evolving manufacturing environment with limited oversight.
Willingness to evaluate and implement new processes, systems, and technologies.

Responsibilities

Provide hands-on technical engineering support and subject matter expertise for a defined family of lost foam castings across the manufacturing process.
Monitor, collect, and analyze operating data to understand the effects of process parameters and identify improvement opportunities.
Provide day-to-day production support by troubleshooting casting defects, process variation, and upstream or downstream conditions.
Lead and support continuous improvement initiatives focused on defect reduction, process stability, productivity, cost reduction, ergonomics, and safety.
Evaluate how foam molding, cluster preparation, coating, sand, compaction, pouring, extraction, finishing, machining, leak testing, painting, and other operations influence final part quality.
Collaborate with operations, quality, maintenance, controls engineering, tooling, and project management teams to implement process improvements.
Support new casting program launches by providing design-for-manufacturability input and participating in tooling, simulation, process development, validation, and part review activities.
Read and interpret casting and machining drawings, tolerances, specifications, CMM reports, inspection results, and other technical requirements.
Contribute to PPAP by supporting process documentation, validation, capability studies, and customer requirements.