Sr. Process Engineer - Dunkirk
About The Position
This position serves as a senior technical role responsible for open-die and GFM forging processes at the Dunkirk facility. The role is accountable for developing, optimizing, and sustaining forging and associated thermal processes to meet customer requirements, ensure stable and capable production, and drive cost competitiveness. The individual will work cross-functionally with operations, maintenance, engineering, and commercial teams, while directly interfacing with customers to support material qualification, process development, and technical issue resolution. This position is expected to grow into the primary technical point of contact for forging processes at the Dunkirk facility.
Requirements
- Bachelor’s or Master’s degree in Metallurgical Engineering or Materials Science
- Minimum 8–12 years of experience in forging and thermomechanical processing of high-performance alloys
Responsibilities
- Establish and own forging process capability for open-die and GFM operations, including control of temperature, strain and reduction, and thermomechanical processing windows.
- Develop, validate, and optimize forging routes and reductions, furnace parameters and heat treatment cycles, and process windows to achieve required mechanical properties and quality.
- Lead customer qualification and development programs, including new material introduction, process qualification and validation, and alignment of customer requirements with plant capabilities.
- Drive cost reduction, yield improvement, and throughput optimization through metallurgical and process improvements.
- Develop and maintain forging programs and tables for 4K press and GFM, process standards for both internal products and outside conversion customers, and disposition and close variances or upgrade to IRR if needed.
- Serve as the technical lead for outside conversion business, including development of forging approaches and routings, support for quoting and cost structure definition, and identification of new opportunities to grow Dunkirk conversion volume.
- Define and implement process monitoring and control systems, including SPC and capability tracking, acquisition and analysis of process data, and correlation of process parameters to product performance.
- Partner with maintenance and engineering to commission and implement new equipment, define and maintain operating envelopes, and improve process reliability through technical understanding.
- Lead technical resolution of internal process issues, customer quality concerns, and deviations and non-conformances.
- Provide technical leadership and mentorship to engineering and operations personnel.
- Define, control, and continuously improve key forging and thermal process parameters- review and update SPC data.
- Monitor and drive product performance (mechanical properties, surface condition, dimensional characteristics, yield).
- Review and interpret customer specifications and ensure technical compliance.
- Maintain process documentation control systems and associated databases.
- Support management review with data-driven analysis and recommendations.
- Interface with customers, sales, and leadership to resolve any differential between customer requirements and SMC capabilities.
- Technical supervision of Dunkirk Processes and employees.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
