Foundry Process Engineer

Waukesha Foundry seeks a Foundry Process Engineer to optimize metal casting operations for high-alloy, complex parts used in energy, defense, and industrial equipment. In this hands-on, on-site role, you will develop and refine processes for molding, melting, pouring, and heat treatment to improve yield, quality, and throughput while maintaining strict safety and reliability standards. You will analyze production data, lead root cause investigations, support new product introductions, and collaborate closely with production, quality, and maintenance teams.

This position offers stable, long-term growth in advanced manufacturing, with opportunities to build specialized technical expertise and contribute to mission-critical castings.

Responsibilities

• Optimize foundry processes for molding, melting, pouring, and heat treatment to improve yield, quality, and throughput
• Develop and update process standards, work instructions, and control plans for high-alloy and complex castings
• Lead root cause analysis for defects and scrap; implement corrective and preventive actions
• Support new product introductions, including process development, trials, and first-article validation
• Collect and analyze production and quality data to drive continuous improvement and cost reduction
• Collaborate with maintenance, quality, and production teams to ensure safe, stable operations
• Specify and support installation, testing, and capability studies for new equipment and tooling
• Train operators and technicians on process parameters, best practices, and safety procedures
• Work with engineering and customers to meet demanding dimensional, metallurgical, and performance specifications
• Ensure compliance with safety, environmental, and quality system requirements

Required Skills

• Metal casting processes (molding, melting, pouring, solidification)
• Metallurgy and heat treatment of high-alloy steels and specialty alloys
• Statistical process control (SPC) and data analysis
• Root cause analysis and problem-solving (5-Why, Fishbone, DMAIC)
• CAD and casting simulation software familiarity
• Process documentation and standard work development
• Lean manufacturing and continuous improvement tools
• Dimensional inspection and GD&T basics
• Industrial equipment troubleshooting and process optimization
• Technical communication and cross-functional collaboration