Foundry Engineer

Position Summary:

Provides foundry process engineering support to improve safety, quality, and productivity

by developing robust casting processes, troubleshooting defects, and implementing controlled documentation and improvement actions.

Essential Functions:

• Support and improve foundry processes including molding, melting, pouring, and finishing activities as applicable.

• Analyze casting defects and lead root cause investigations; implement corrective and preventive actions.

• Develop and maintain process documentation (work instructions, parameters, control plans) under change control.

• Partner with Quality on inspection strategy, defect detection, and containment activities.

• Support process trials and validation; document results and standardize successful changes.

• Collaborate with Patternmaking and Production on tooling/pattern improvements and process capability.

• Identify and execute continuous improvement projects to reduce scrap, rework, and cycle time.

• Support safety and environmental compliance by integrating hazard controls into process design and standard work.

• Provide technical support to supervisors and operators; train teams on process changes and best practices.

• Track foundry KPIs and report trends and improvement progress to leadership. Additional Skills by Level

Level I: Supports documentation and basic troubleshooting with guidance; learns foundry standards and defect modes.

Level II: Independently leads defect elimination and process optimization projects; improves stability and capability.

Level III: Leads advanced foundry process development and modernization initiatives; sets site-wide standards.

Job Requirements and Qualifications

Education, Experience, or Formal Training:

• Bachelor’s degree in Engineering (Metallurgical/Materials/Mechanical/Manufacturing) or equivalent experience.

• 3+ years foundry or casting process experience preferred.

• Strong analytical/problem-solving skills and comfort working in industrial environments.

Working Environment:

Foundry environment with heat, dust, noise, and industrial hazards; PPE required; may require extended hours for trials or urgent defect containment.

Physical Demands:

• Frequent walking/standing; ability to wear PPE including heat-resistant gear as required.

• Occasional lifting up to 30 lbs (samples, tools) and ability to work near hightemperature processes safely.

KPIs:

• Scrap rate in foundry (by defect category)

• Rework rate (foundry-related)

• First Pass Yield (foundry processes)

• Defect recurrence rate after corrective actions

• Corrective action closure time and effectiveness

• Cycle time/throughput for key foundry operations

• Process adherence audit pass rate

• Safety incidents/near-misses in foundry areas

• Control plan coverage for critical foundry processes

• Training completion for process changes

SMART Goals:

• Reduce foundry scrap by 12% within 9 months by eliminating top-3 defect drivers using structured RCA.

• Reduce rework by 10% within 2 quarters through improved process controls and operator training.

• Increase foundry FPY by 6 percentage points within 2 quarters via standard work and control points.

• Reduce defect recurrence by 25% within 6 months by verifying corrective action effectiveness and updating documentation.

• Close 90% of foundry corrective actions within 30 days for 2 consecutive quarters through escalation routines.

• Improve throughput on one foundry constraint operation by 8% within 6 months through workflow and setup improvements.

• Achieve ≥95% process adherence in monthly audits within 120 days by reinforcing standard work and training.

• Increase near-miss reporting by 25% within 6 months and close actions within 14 days.

• Implement control plans for 100% of identified critical foundry processes within 120 days.

• Achieve 100% training completion for critical foundry process changes within 10 business days for 3 consecutive months.