Process Quality Engineer

Responsibilities:

- Support and improve Foundry processes including raw material charging, melting, metal treatment, chemistry control, DC casting, homogenization, and related material handling processes.

- Monitor and analyze key process parameters, process capability, scrap, yield, downtime, and quality performance to identify improvement opportunities.

- Lead or support scrap reduction, yield improvement, cost reduction, and process optimization projects.

- Establish, document, and maintain process standards, operating parameters, recipes, SOPs, work instructions, and process controls.

- Perform process trials, data analysis, and structured problem solving to improve process stability and product quality.

- Lead and participate in root cause analysis and corrective actions for process and product nonconformities.

- Develop and maintain Process FMEAs and Control Plans and ensure controls reflect actual process risks and operating conditions.

- Identify process risks and implement appropriate prevention, detection, and error-proofing controls.

- Support SPC, process capability analysis, Measurement System Analysis, and other statistical quality tools as applicable.

- Organize and conduct process, layered, and Quality System audits and follow corrective actions through completion.

- Support internal and external Quality System audits and ensure Foundry processes comply with applicable QMS requirements.

- Lead and support Kaizen and Continuous Improvement activities using Lean/Six Sigma and structured problem-solving methodologies.

- Analyze workflow and value streams to identify waste, process variation, bottlenecks, and opportunities for improved efficiency.

- Establish and monitor Foundry KPIs related to scrap, yield, quality, process compliance, and continuous improvement.

- Partner with Operations and Maintenance to troubleshoot equipment and process-related issues affecting product quality or process stability.

- Review process changes, equipment modifications, and new process implementations to ensure quality and process risks are appropriately addressed.

- Provide technical training and guidance to production personnel on process standards, quality controls, and standardized work.

- Ensure process changes and improvements are properly documented, communicated, implemented, and sustained.

- Promote continuous improvement and a data-driven approach to process and quality performance.

- Perform other process engineering, quality, and continuous improvement activities as required.

Education:

- Bachelor’s degree in Engineering, Materials Science, Metallurgy, Manufacturing Engineering, Mechanical Engineering, or related technical field.

Skills:

- Critical Thinking — Using logic and reasoning to both develop solutions and identify the strengths and weaknesses of alternative solutions, conclusions or approaches to problems.

- Monitoring / Documentation— Monitoring/Assessing current production procedures and standards to identify inefficiencies. Maintaining all production documentation, including owner manuals and relevant documentation for machinery. This responsibility includes updating all documentation when processes change

- Teamwork – Job requires the ability to function as part of a small team, as well as the ability to work independently.

- Integrity — Job requires being honest and ethical.

- Time Management — Managing one's own time and the time of others.

- Dependability — Job requires being reliable, responsible, and dependable, and fulfilling obligations.

- Production and Processing — Knowledge of raw materials, production processes, quality control, industry standards, costs, and other techniques for maximizing the effective manufacture and distribution of goods.

- Good verbal and written communication skills to technical and non-technical audiences of various levels in the organization, e.g., executive, management, individual contributors

- Excellent analytical, decision-making, problem-solving, resourceful and proactive in gathering information and sharing ideas

Qualifications:

- Bachelor’s degree in Engineering, Materials Science, Metallurgy, Manufacturing Engineering, Mechanical Engineering, or related technical field.

- 2+ years of experience in manufacturing, process engineering, quality engineering, or continuous improvement preferred.

- Experience in aluminum, metals, casting, foundry, or other heavy manufacturing environments preferred.

- Working knowledge of PFMEA, Control Plans, root cause analysis, corrective action, SPC, and process capability.

- Working knowledge of Lean Manufacturing and Six Sigma tools.

- Experience developing or maintaining SOPs, work instructions, and process documentation.

- Experience with process and/or Quality System auditing preferred.

- Strong analytical and data-driven problem-solving skills.

- Ability to work effectively on the manufacturing floor and collaborate with Operations, Quality, Maintenance, and Engineering.

- Strong written and verbal communication skills.

Working Conditions:

- This position works in a manufacturing environment.

- This position operates in shop floor and office environment

- Involves: long periods of shop floor activities, frequent stooping, and bending

- This position routinely uses standard office equipment

The annual base salary range for this position is $97,500 - $110,000. If you are hired, your annual base pay will be determined based on factors such as geographic location, skills, education, and/or experience. In addition to those factors, we believe in the importance of pay equity and consider internal equity of our current team members as part of any final offer. Please keep in mind that the range mentioned above is the full base pay range for the role.