Process Engineer - High Pressure Die Cast (HPDC)

Brunswick Boat Group•Fond du Lac, WI

16d•Onsite

About The Position

As part of the Plant 17 Engineering team, the Process Engineer serves as a technical leader for Mercury’s Aluminum High Pressure Die Cast (HPDC) Foundry. The role is accountable for developing, controlling, optimizing, and sustaining die-casting processes to meet quality, cost, delivery, and safety objectives. The position is onsite at Plant 17 in a foundry environment, with less than 5% travel and no direct reports. The engineer owns the HPDC process, including metal delivery, shot profile development, die thermal management, spray and extraction cycles, part removal, trimming, and secondary operations. The role analyzes production data, leads continuous improvement, collaborates with engineering and operations teams, supports traceability and data-collection advances, and helps launch new tooling through design-for-manufacturing recommendations and casting trials. Limited part-family and backup responsibilities are included. The stated hiring range is $73,600 to $106,200 annually. The position is eligible for an annual discretionary bonus and Brunswick benefits. Applicants must already be authorized to work in the United States; visa sponsorship and relocation assistance are not available.

Requirements

Willingness to work hands-on at the shop-floor level in a foundry environment.
Willingness to try new processes, systems, and technologies, including those new to the foundry.
Strong cross-functional collaboration and communication skills with support teams and operations management.
Ability to make independent, data-driven decisions supported by sound logic.
Ability to work effectively in a fast-paced, constantly changing manufacturing environment with moderate supervision.
Ability to use a systems approach, considering all plant factors when solving problems and making improvements.
Self-driven interest in professional growth through training, professional organizations, continuing education, and certifications.

Nice To Haves

Bachelor’s degree in Manufacturing, Mechanical, Electrical, or Controls Engineering, or a related engineering degree.
Three or more years of foundry experience with direct responsibility for controlling process-related parameters.
Proven ability to apply casting process simulation to optimize processes and reduce defects.
Proficiency with PLCs, industrial controls, and robotics, specifically Allen Bradley and ABB.
Strong knowledge of Microsoft applications, including Excel, Access, SQL Management Studio, Teams, SharePoint, Planner, CoPilot, and PowerBI.
Experience using and providing direction for shop-floor dashboards.
Green Belt Certification and demonstrated success applying Lean Manufacturing and Six Sigma methodologies to solve problems.
Ability to work with large amounts of data quickly and efficiently to uncover solutions.
Highly engaged contribution to PFMEA and control plan discussions.
Experience with casting simulation software; MagmaSoft HPDC module is preferred.

Responsibilities

Develop, control, optimize, and sustain the HPDC process to meet quality, cost, delivery, and safety objectives.
Own and control metal delivery, shot profile development, die thermal management, spray and extraction cycles, part removal, trimming, and secondary operations.
Monitor, analyze, and interpret process and production data to understand parameter interactions, improve process capability, prevent defects, and ensure consistent casting quality.
Lead continuous improvement initiatives involving quality, process stability, machine uptime, cost reduction, and safety through structured problem solving and standardization.
Serve as the casting process technical expert when collaborating with controls engineering, maintenance, quality, tooling, and operations teams.
Lead and support advancements in part traceability, in-process inspection, and manufacturing data-collection systems.
Support new tooling launches by providing Design for Manufacturing recommendations and leading initial casting trials.
Handle limited part-family and backup responsibilities.