Foundry Process Engineer - Melting

Purpose

The Tower/Process Engineer will be responsible for overseeing and coordinating production in the Melting and Pouring departments through the monitoring of hourly personnel, furnace operation via remote console from the Melt Tower, refractory maintenance, and general departmental upkeep. This position will also assist in development, monitoring, and coordinating of production standards and methods for the effective utilization of resources and meeting customer requirements through controlling and maintaining departmental process control standards.

This position will also support the installation, commissioning, and ongoing operation of a new Induction Furnace scheduled to be introduced at the plant.

Principal Accountabilities

1. Supervision and coordination of hourly personnel to optimize departmental performance.
2. Adjust workforce to staffing requirements.
3. Setting and adjustment of process controls including, but not limited to, charge chemistries and melt chemistries.
4. Maintenance of electric arc furnaces (EAF) through refractory upkeep and scheduled repairs with the maintenance department.
5. Operation of EAFs from the Melt Tower.
6. Maintain and control of ISO system standards and calibration systems. Also, accept accountability for routine auditing of the plant operations against internal ISO system standards. Direct operational adherence to Quality Control and ISO standard operating procedures throughout the department.
7. Assist in reduction of cost and improvement in efficiencies through development of systems, standards, and procedures and monitoring of production phases of the products.
8. Maintain production reports and track applicable departmental data and metrics.
9. Confer with supervision and other personnel to implement operating procedures and provide technical information to Operations.
10. Provide engineering and operational support for the integration and operation of the new Induction Furnace, including coordination with maintenance, production, and safety teams.
11. Additional duties and responsibilities not yet defined to assure the safe and efficient operation of the melting shop and all equipment necessary for this purpose.

Quality

1. Develop and audit quality control standards.
2. Maintain and adhere to ISO standards, including but not limited to the Quality Policy Statement and the Quality Control Procedures Manual.
3. Ensure employees are completing assigned training materials, including reading and review of work instructions.
4. Ensure hands-on training matches work instruction documentation.

Safety

1. Monitor workforce activities to control the number of recordable doctor cases and lost time injuries.
2. Enforce safety rules.
3. Conduct safety meetings and safety contacts as needed.
4. Investigate and report on all near misses and injuries and develop corrective action plans when necessary.
5. Conduct annual review of “Right-To-Know” material.
6. Maintain showcase housekeeping.

Cost

1. Operate efficiently to control direct labor and material costs.
2. Encourage cost reduction ideas.

Position Qualifications

1. Bachelor’s degree in Mechanical, Electrical, Industrial, or Materials Science Engineering with a minimum of 1–3 years of experience in an industrial production environment.
2. Familiarity with Quality Control standards and ISO systems.
3. Excellent oral and written communication and group presentation skills.
4. Demonstrated initiative and ability to work both independently and in team settings.
5. Ability to create, contribute, and accept ideas for changes in procedures and processes necessary to operate the department in a safe, efficient, and effective manner.