Process Engineer - High Pressure Die Cast (HPDC)

Brunswick Corporation•Fond du Lac, WI

18d•$73,600 - $106,200•Onsite

About The Position

As part of the Plant 17 Engineering team, the Process Engineer serves as a key technical leader within Mercury’s Aluminum HPDC Foundry. The role is accountable for developing, controlling, optimizing, and sustaining the high-pressure die casting process to meet quality, cost, delivery, and safety objectives. The position works onsite in a foundry environment, with travel required of less than 5%. It has no direct reports. The hiring range is $73,600 to $106,200 annually, and the role is eligible for an annual discretionary bonus. Applicants must already be authorized to work in the United States; visa sponsorship and relocation assistance are not available.

Requirements

Desire to work hands-on at the shop-floor level within a foundry environment.
Willingness to try new processes, systems, and technologies that may be 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 excel in a fast-paced, constantly changing manufacturing environment while working effectively with moderate supervision.
Ability to apply a systems approach and consider all plant factors when solving problems and making improvements.
Self-driven commitment to 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 use 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, preferably MagmaSoft HPDC module.

Responsibilities

Own and control the HPDC process, including 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 focused on 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 (DFM) recommendations and leading effective initial casting trials.
Provide limited part-family and backup responsibilities.