Senior Process Metallurgist

Charter Manufacturing•Woodstock, IL

13d•Onsite

About The Position

As a Senior Process Metallurgist, you will provide technical leadership with a strong focus on metallurgical and process engineering across the Melt, Laboratory, and Continuous Casting operations. You will apply materials science, metallurgy, and manufacturing-process expertise to improve safety, quality, productivity, and cost. Partnering closely with Operations and cross-functional teams, you will troubleshoot complex technical issues, strengthen process controls and standards, optimize melting and casting practices, support new-product development, and implement sustainable process improvements. This role serves as a primary technical resource for manufacturing process performance and product quality.

Requirements

Bachelor’s Degree in Metallurgical Engineering, Materials Science, or a related engineering discipline.
Five or more years of experience in a metallurgical, materials, manufacturing, or process engineering environment.
Strong understanding of metallurgy, materials science, cast iron manufacturing, process control, and data analysis.
Demonstrated success solving complex technical problems and improving manufacturing processes.
Strong analytical, troubleshooting, root cause analysis, and problem-solving skills.
Ability to lead cross-functional projects and influence others without direct authority.
Strong verbal, written, and presentation skills.
Experience with SolidWorks 2D/3D CAD software, or willingness to learn, to support tooling, equipment, and process improvements.
Proficiency with Microsoft Office and manufacturing data analysis tools.
Ability to manage multiple priorities in a fast-paced manufacturing environment.
Demonstrated commitment to safety, quality, and continuous improvement.
Willingness to travel up to 10%.

Nice To Haves

Master’s Degree in Metallurgical Engineering, Materials Science, Engineering, Operations Management, or a related field.
Experience with induction melting and production of gray and ductile cast iron.
Experience with continuous casting operations and cast iron manufacturing.
Experience with metallurgical laboratory equipment, including optical emission spectrometers and LECO analyzers.
Experience in defect analysis, failure analysis, and customer-facing technical support.
Experience developing new or improved products.
Experience with ISO or Quality Management Systems.
Experience with MES and ERP systems supporting manufacturing processes; Oracle ERP experience is a plus.
Lean Manufacturing and/or Six Sigma Green Belt certification, or equivalent continuous-improvement experience.
Experience leading or supporting capital improvement projects involving manufacturing equipment, tooling, furnaces, holders, or process improvements.
Proficiency with statistical analysis, process mapping, and data visualization tools.

Responsibilities

Provide technical leadership for Melt, Laboratory, and Continuous Casting processes by developing and improving metallurgical standards, manufacturing processes, and operating practices.
Develop and improve melt recipes, process instructions, and standards for molten metal processing, product analysis, and product release.
Evaluate and adjust manufacturing processes based on raw material quality, chemical composition, cost, product requirements, and process performance.
Improve melting and continuous casting processes, including die and cooler design, crucible design, refractory practices, molten metal handling, and critical process variables.
Strengthen metallurgical quality and process consistency for gray and ductile cast iron products.
Partner with Operations to troubleshoot manufacturing, process, and quality issues; lead root cause analysis and implement sustainable corrective actions.
Analyze manufacturing, laboratory, quality, and process data to identify trends, reduce manufacturing losses, improve yield, and strengthen process capability.
Lead process improvement projects through data analysis, process validation, production trials, and implementation of sustainable improvements.
Investigate and resolve quality problems identified during manufacturing or through customer returns, including defect and failure analysis.
Apply process engineering and continuous-improvement tools, including Design of Experiments, statistical analysis, process mapping, DMAIC, root cause analysis, and Lean principles.
Maintain MES process master data and provide technical support for manufacturing system enhancements, troubleshooting, and process optimization.
Support capital projects involving manufacturing equipment, tooling, furnaces, holders, refractory systems, and process improvements.
Serve as the primary technical resource for new-product quoting by evaluating manufacturing feasibility, process capability, and technical risk.
Partner with Procurement in qualifying new suppliers and ensuring incoming raw materials meet required technical and quality standards.
Support the development and qualification of new or improved products, materials, manufacturing technologies, and process capabilities.
Collaborate with Operations, Quality, Maintenance, Engineering, Supply Chain, Sales, and Technical Services to solve technical problems and support strategic initiatives.
Support Commercial and Sales teams as a technical resource for customer application questions, quality concerns, processing recommendations, and product performance.
Develop and maintain manufacturing standards, work instructions, operating procedures, and technical documentation.
Share technical knowledge and mentor employees on metallurgy, materials science, process controls, manufacturing processes, and continuous-improvement practices.
Support Environmental, Quality, and Safety Management Systems and ensure compliance with company policies and regulatory requirements.