Senior Process Control Technician – Die Cast Parameters & Defect Reduction

Location: Cedarburg, WI |
Schedule: Full-time, 3rd Shift, on-site |
Compensation: Up to $41.00/hr ($85,280/yr baseline depending on experience)

A leading North American die casting manufacturer is seeking a Senior Process Control Technician to oversee process integrity on its 3rd shift production floor. This direct-hire role is responsible for monitoring critical variables on automated, high-pressure aluminum casting cells, driving down scrap, troubleshooting complex part defects, and ensuring compliance with tier-one OEM quality standards at an ISO-certified facility known for strong employee tenure and stability.

• Continuously track and analyze critical process variables including melt temperatures, shot profiles, injection speeds, intensification pressures, cycle times, and die lubrication
• Perform root-cause analysis on defect issues such as porosity, cold shuts, soldering, blisters, flash, misruns, and thermal shrinkage
• Set up, fine-tune, and validate die casting process parameters for new product launches, die tryouts, and existing production runs
• Establish, document, and maintain accurate process setup sheets and operating instructions for setup techs and machine operators
• Collaborate with quality and engineering teams to validate process changes, improve first-pass yield, and minimize scrap rates
• Utilize real-time process monitoring systems and review X-ray inspection data to ensure parts meet customer specifications
• Coach and train machine operators and setup technicians on standardized process parameters and operational best practices

• Demonstrated career stability with a minimum of 2+ years of tenure at each previous employer
• 2+ years of hands-on experience in process control within a manufacturing environment
• Strong problem-solving skills with the ability to interpret process monitoring data, thermal profiles, and quality reports
• Must reside within a 45 minutes maximum commute of the Cedarburg / Greater Milwaukee, WI area
• High School Diploma or GED required
• Must have U.S. work authorization without sponsorship

• Manufacturing process experience in aluminum die casting, plastic injection molding, or metalworking preferred
• Technical diploma or vocational degree in manufacturing technology or metallurgy preferred
• Specialized background in high-pressure aluminum die casting, vacuum-assisted die casting, or molten metal thermal management
• Familiarity with robotic automation, real-time shot monitoring software, X-ray inspection analysis, and IATF 16949 quality guidelines
• Practical experience with Six Sigma methodology, 5S, Pareto analysis, or formal root-cause analysis frameworks

• Starting pay up to $41.00/hr ($85,280/yr baseline depending on experience)
• Pay-for-performance bonus opportunities
• 401(k) with company match
• Full health/dental/vision benefits
• Opportunities to earn additional hours of bonus PTO per year for strong attendance

This direct-hire position offers outstanding hourly earnings, long-term stability, strong 401(k) matching, and structured career advancement opportunities within an ISO-certified facility where 40% of the team has over a decade of tenure.