Casting Production Supervisor

Description

Duties/Responsibilities

• Supervise daily aluminum casting operations, including melting, furnace operation, molten metal handling, casting, trimming, finishing, and material movement activities. 

• Ensure production schedules are achieved while maintaining safety, quality, cost, and delivery targets. 

• Monitor and control critical casting parameters such as melt temperature, metal chemistry, die temperatures, cycle times, and casting yields. 

• Lead and support production teams operating casting cells, furnaces, robotic equipment, trimming presses, and finishing operations. 

• Coordinate alloy changes, product changeovers, and startup activities to minimize downtime and maximize productivity. 

• Work closely with Quality, Engineering, Maintenance, and Tooling departments to resolve casting defects, equipment issues, and process variations. 

• Analyze and reduce casting defects including porosity, shrinkage, inclusions, cold shuts, misruns, and dimensional nonconformities. 

• Drive continuous improvement initiatives focused on scrap reduction, yield improvement, cycle time optimization, and Overall Equipment Effectiveness (OEE). 

• Ensure compliance with all foundry safety standards related to molten aluminum handling, lockout/tagout, confined space entry, PPE requirements, and environmental regulations. 

• Monitor labor utilization, production performance, downtime events, and key manufacturing metrics; develop corrective action plans when targets are not achieved. 

• Support implementation of Lean Manufacturing, 5S, TPM, and continuous improvement programs throughout the casting operation. 

• Conduct daily production meetings and communicate plant goals, safety concerns, quality issues, and production priorities to team members. 

• Develop and mentor employees through training, performance management, and succession planning activities. 

• Coordinate preventive maintenance activities on furnaces, casting machines, conveyors, trimming equipment, and auxiliary systems to ensure equipment reliability.

Requirements

Required Skills/Abilities: 

•  Associate's or Bachelor's degree in Engineering, Manufacturing, Metallurgy, Industrial Technology, or related field preferred; equivalent experience considered. 
•  Minimum 3–5 years of supervisory experience in an aluminum casting, foundry, die casting, permanent mold, or high-volume manufacturing environment. 
•  Strong understanding of aluminum melting, casting processes, metal flow characteristics, and casting quality requirements. 
•  Experience managing furnace operations, molten metal safety procedures, and casting process controls. 
•  Knowledge of casting defect analysis, root cause investigation, corrective actions, and quality systems. 
•  Familiarity with automotive manufacturing standards, APQP, PFMEA, Control Plans, and IATF 16949 requirements preferred. 
•  Strong leadership, coaching, and team-building abilities in a fast-paced manufacturing environment. 
•  Experience utilizing ERP/MES systems and production reporting tools. 
•  Knowledge of Lean Manufacturing, Six Sigma, 5S, and continuous improvement methodologies. 
•  Ability to make sound decisions under pressure while balancing safety, quality, delivery, and cost objectives. 
•  Excellent communication, organizational, and problem-solving skills.

Physical Requirements: 

•  Ability to work in a high-temperature manufacturing environment with exposure to molten aluminum, furnaces, and industrial equipment. 
•  Ability to wear required personal protective equipment (PPE), including heat-resistant clothing, face shields, gloves, hearing protection, and safety footwear. 
•  Ability to stand and walk for extended periods throughout the production area. 
•  Ability to lift up to 35 pounds occasionally. 
•  Ability to climb stairs, ladders, platforms, and access elevated work areas. 
•  Ability to bend, squat, kneel, and reach during inspections and troubleshooting activities.