Process Engineer - Cast House

Hydro•Phoenix, AZ

About The Position

The Cast House Process Engineer is a dedicated engineering resource supporting process performance and continuous improvement within Hydro’s Phoenix Cast House. The role optimizes aluminum melting, alloying, casting, and related manufacturing processes to promote safe, efficient, and cost-effective operations. It provides technical engineering support to improve metal recovery, product quality, equipment reliability, and overall cast house performance. The engineer partners with Operations, Maintenance, Quality, and HSE teams to identify improvement opportunities, troubleshoot production challenges, reduce scrap, and implement sustainable solutions. The role supports process stability, standardization, and continuous improvement while maintaining compliance with safety, environmental, and quality standards.

Requirements

Bachelor’s degree in Metallurgical Engineering, Materials Science, Mechanical Engineering, Chemical Engineering, or a related technical field.
3–5 years of process engineering, manufacturing engineering, or related experience in an industrial manufacturing environment.
English speaking.

Nice To Haves

Spanish language skills.
Working knowledge of industrial manufacturing equipment, including hydraulic and pneumatic systems, process controls, and manufacturing quality systems.
Experience with statistical process control (SPC), process capability analysis, and manufacturing performance metrics.
Experience with Lean Manufacturing, Six Sigma, Kaizen, and structured problem-solving tools.
Knowledge of aluminum alloys, metallurgy, solidification, and casting defect prevention.
Knowledge of ISO 9001, IATF 16949, and automotive manufacturing quality requirements.
Experience supporting capital improvement projects, equipment installations, and process automation.
Demonstrated experience in process optimization, root cause analysis, and continuous improvement.
Strong analytical skills and the ability to interpret manufacturing data and implement measurable improvements.
Strong communication, project management, and cross-functional collaboration skills.
Ability to work in an industrial manufacturing environment and provide technical support across production shifts as needed.

Responsibilities

Use manufacturing and process data to identify root causes, implement improvements, and evaluate their sustained effects on quality, reliability, downtime, and throughput.
Analyze and optimize aluminum melting, holding, alloying, metal treatment, and casting processes.
Monitor and analyze process parameters such as furnace temperatures, melt rates, casting temperatures, cycle times, and metal chemistry; identify trends and opportunities using production data.
Improve metal recovery, reduce dross generation and melt loss, minimize scrap and downtime, improve quality, and increase production efficiency.
Develop, implement, and maintain standardized operating procedures and process control parameters.
Evaluate process capability and identify improvements that increase casting consistency and billet quality.
Provide technical support for furnace operations, casting equipment, molten metal transfer, and related processes.
Support introduction of new alloys, process technologies, and equipment improvements, including installation, layout, startup, and process optimization.