Senior Metallurgy & Process Leader; Casting

Charter Manufacturing is a fourth-generation family-owned business where our will to grow drives us to do it better. Join the team and become part of our family!

Charter Casting is hiring a Senior Process Metallurgist!

Alternative Job Titles: Senior Manufacturing Metallurgist, Lead Process Metallurgist, Senior Metallurgical Engineer



Job Summary

As a Senior Process Metallurgist, you will provide technical leadership with a strong focus on metallurgical and process engineering across the Melt, Laboratory, and Continuous Casting operations. You will apply materials science, metallurgy, and manufacturing-process expertise to improve safety, quality, productivity, and cost.

Partnering closely with Operations and cross-functional teams, you will troubleshoot complex technical issues, strengthen process controls and standards, optimize melting and casting practices, support new-product development, and implement sustainable process improvements. This role serves as a primary technical resource for manufacturing process performance and product quality.

Position Specifics

• Location:
  
  Woodstock, IL
• Schedule:
  
  Onsite
• Travel:
  Up to 10% travel
• Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor employment visas at this time.

• Provide technical leadership for Melt, Laboratory, and Continuous Casting processes by developing and improving metallurgical standards, manufacturing processes, and operating practices.
• Develop and improve melt recipes, process instructions, and standards for molten metal processing, product analysis, and product release.
• Evaluate and adjust manufacturing processes based on raw material quality, chemical composition, cost, product requirements, and process performance.
• Improve melting and continuous casting processes, including die and cooler design, crucible design, refractory practices, molten metal handling, and critical process variables.
• Strengthen metallurgical quality and process consistency for gray and ductile cast iron products.

• Partner with Operations to troubleshoot manufacturing, process, and quality issues; lead root cause analysis and implement sustainable corrective actions.
• Analyze manufacturing, laboratory, quality, and process data to identify trends, reduce manufacturing losses, improve yield, and strengthen process capability.
• Lead process improvement projects through data analysis, process validation, production trials, and implementation of sustainable improvements.
• Investigate and resolve quality problems identified during manufacturing or through customer returns, including defect and failure analysis.
• Apply process engineering and continuous-improvement tools, including Design of Experiments, statistical analysis, process mapping, DMAIC, root cause analysis, and Lean principles.

• Maintain MES process master data and provide technical support for manufacturing system enhancements, troubleshooting, and process optimization.
• Support capital projects involving manufacturing equipment, tooling, furnaces, holders, refractory systems, and process improvements.
• Serve as the primary technical resource for new-product quoting by evaluating manufacturing feasibility, process capability, and technical risk.
• Partner with Procurement in qualifying new suppliers and ensuring incoming raw materials meet required technical and quality standards.
• Support the development and qualification of new or improved products, materials, manufacturing technologies, and process capabilities.

• Collaborate with Operations, Quality, Maintenance,…