Sr. Metallurgist Process Engineer

Overview

System One is currently seeking a Sr. Process Engineer for an industry-leading client in the Youngstown, OH area.

This Senior Process Engineer position involves directing and overseeing casting and metallurgical programs that advance operational capabilities, production processes, and product innovation. The individual in this role will concentrate on establishing and refining procedures that achieve customer requirements for quality standards, reliability, and delivery timelines in a safe and economical manner. Serving as the primary technical authority on metallurgy and casting operations, this engineer will employ analytical, data-based approaches and maintain an innovative mindset to address sophisticated challenges.

The position requires collaboration across departments including Production, Engineering, Supply Chain, and Quality Assurance, with direct involvement alongside production floor staff to execute solutions. External interactions with clients and suppliers are also required, following appropriate confidentiality and disclosure agreements.

Safety Responsibilities:

• Maintain individual and team adherence to company policies and regulatory requirements for safety, environmental protection, and occupational health
• Partner with the EHS Manager to prioritize safety in all process modifications and equipment installations
• Engage in safety audits and accident reviews
• Champion a safety-oriented culture throughout all operational areas

Operational Responsibilities:

• Direct bimetallic casting operations encompassing product formulations, evaluation procedures, non-destructive examination, and outsourced activities
• Refine casting parameters including heating duration, rotational speed/centrifugal force, mold temperature preparation, molten metal quality, and insert bonding
• Coordinate product priorities and evaluation schedules with furnace production planning
• Enhance material efficiency in casting operations while preserving product quality
• Track furnace operational status and arrange maintenance activities and enhancements
• Guarantee thorough and precise documentation of casting logs and production orders
• Administer process standards and personnel training needs
• Function as the organizational authority on materials science and additive manufacturing throughout all facilities
• Keep abreast of advanced casting methodologies and preserve casting as a fundamental capability

Development & Enhancement:

• Direct product innovation projects, including novel insert/matrix compositions for barrel products
• Deploy systematic problem-solving methodologies such as Design of Experiments, Root Cause Analysis, Failure Mode Effects Analysis, and Six Sigma principles
• Apply heat transfer modeling and computational techniques to enhance casting operations
• Execute strategies to elevate product quality and uniformity
• Verify adherence to quality management systems and protocols
• Examine customer feedback and internal corrective action requests; facilitate root-cause determination and remedial measures
• Create and communicate performance indicators using Statistical Process Control, Statistical Quality Control, and Lean principles

Client Relations Support:

• Contribute to Specific Product Design activities to fulfill client requirements
• Evaluate test outcomes for specification conformance
• Spearhead defect mitigation efforts addressing porosity, surface irregularities, and fracturing
• Address customer concerns through direct communication and technical evaluation

Additional Duties:

• Complete supplementary assignments as necessary to advance organizational goals
• Sustain regular on-site attendance to build robust relationships and encourage team synergy
• Undertake travel commitments (10–20%, potentially international) to fulfill customer and operational requirements

Professional Background

Required:

• At least 5 years in a supervisory or leadership capacity within centrifugal casting metallurgy, including direct production floor involvement
• Demonstrated track record leading sophisticated initiatives in product and process innovation

Academic Credentials and

Competencies:

• Bachelor's degree in Materials Science, Mechanical Engineering, Metallurgical Engineering, or comparable discipline
• Robust foundation in materials or mechanical engineering principles
• Comprehensive knowledge of casting variables and defect formation mechanisms
• Direct experience with centrifugal or specialized casting operations
• Familiarity with thermal simulation, foundry operations, and insert bonding methodologies
• Strong inquisitive nature and enthusiasm for cutting-edge technology
• Superior communication capabilities for both technical and general audiences
• Proven ability to work effectively across multiple departments
• Strong action orientation and evidence-based decision-making approach
• Outstanding project coordination and planning capabilities
• Advanced analytical and critical reasoning skills
• Competency in Lean/Six Sigma methodologies
• Proficient use of Microsoft Office applications (Excel,…