We are currently seeking a
Foundry Metallurgist /Casting Engineer for our Steel and Iron Foundry in
Decatur, Illinois.PURPOSE OF POSITION Reporting directly to the Foundry Technical Manager, the Foundry Metallurgist /Casting Engineer is responsible to utilize process control and experience to insure the production of consistently high quality castings.
TASKS & RESPONSIBILITIES SAFETY:- Review and approve foundry work instructions and PPE requirements to ensure safe operation.
- Ensure that outside vendors adhere to plant safety regulations and that MSDS for new and existing materials are reviewed, approved and filed.
QUALITY:- Review foundry process control techniques to ensure measuring and recording techniques employed are accurate and that monitoring protocols are adequate to effectively control foundry processes and facilitate troubleshooting.
- Manage process control data within QCS and effect process changes to reduce scrap rates and improve product quality.
- Maintain an extensive knowledge of applicable quality standards and procedures. Establish/adhere, audit and enforce vendor quality procedures and specifications.
- Rig new manganese castings as well as improve rigging on current products. Provide input to the methods drawings in order to maintain legacy of successful rigging.
- Design and carry out test trials targeting product, process, and quality improvement.
- Maintain accurate records of materials, melt chemistry, and consumables for traceability and cost accuracy.
- Conduct root-cause investigations of casting defects using metallurgical analysis and process-troubleshooting methods.
- Train and assist foremen, supervisors, and operators in metal quality, sand control, and casting best practices.
- Monitor and adjust sand-system parameters to maintain consistent mold quality while reviewing system trends and implementing corrective actions to eliminate variation.
- Review welding-repair procedures for manganese castings, support welders with proper preheat, interpass-temperature control, and filler-metal selection, investigate weld-repair defects, and implement process-driven corrective actions to ensure all repairs meet metallurgical and customer specifications.
- Verify heat-treatment furnace-temperature uniformity, sensor calibration, and quench-system parameters while conducting hardness testing and microstructural evaluations to confirm heat-treat results.
- Troubleshoot heat-treatment issues such as overheating, soft spots, and distortion, and implement the necessary process improvements.
- Troubleshoot and resolve issues with critical laboratory and process-control equipment - including the spectrometer, sand-lab testing instruments, and heat-treatment system components - to ensure accurate and reliable operation.
ON-TIME DELIVERY:- Develop and implement plans to improve foundry productivity.
- Ensure timely development and verification of moulding and rigging.
- Manage relationships with internal/external customers and vendors to ensure appropriate communications to prevent delays due to sourcing or delivery issues.
- Collaborate with design and production teams to optimize manufacturing processes.
COST:- Establish metrics and data analysis to identify and trend cost concerns.
- Prepare cost estimates and schedules.
- Conduct failure analysis and develop and implement improvement plans.
- Ensures foundry processes minimize scrap and optimize yield.
PEOPLE:- Coach and mentor foundry technical and operating personnel.
ENVIRONMENTAL:- Adhere to Nortrak's Environmental Procedures, Practices and Policies.
Other duties as assigned.
QUALITIFCATIONS:EDUCATION:- Bachelor's degree in Engineering, preferably in Material Science or Metallurgy.
FIELD OF EXPERIENCE:- At least five (5) years' experience in steel foundry in an engineering or technical position.
- Experience with low volume/high component mix environment.
- Ability to troubleshoot foundry processes at the shop level.
- Experience with Data Analysis tools Mini-tab or other Statistical software.
- Strong interpersonal, written, and oral communication skills are required.
- Must possess excellent negotiations, interpersonal and oral and written communication skills.
- Computer literate including Microsoft Excel Spreadsheets. SAP knowledge and/or experience would be an asset.
- Proficiency in metallurgical testing and analysis methods.
- Understanding of thermodynamics, phase diagrams, and material properties.
- Attention to detail and high standards of quality.
- Familiarity with metallurgical software and analysis tools.
PHYSCIAL DEMANDS:- Prolonged periods of sitting at a desk and working on a computer; occasional standing and walking for your scheduled shift.
- Must remain stationary for extended periods and move throughout the building to access files.
- Must work effectively in a noisy environment.
- Ability to lift and move equipment or objects up to 20-25 pounds occasionally.
- Visual requirements include close, distance, color, peripheral vision, depth perception, and the ability to adjust focus.
- Occasional travel required, involving walking, standing, sitting, and driving for varying durations.
- Site inspections required to identify and address safety concerns.
- Frequent use of hands and arms for dialling phones and using a computer mouse.
Working Location:salary:- $75,000/year - $90,000/year
Benefits:- A supportive, family oriented Nortrak Blue culture.
- We provide an environment where Health and Safety is our #1 priority.
- Career development opportunities and competitive pay progression.
- Competitive medical, dental & vision benefits.
- Company paid life and disability insurance.
- Paid holidays and vacation.
- Retirement plan with matching contributions.
- Tuition Assistance Program.
- Wellness Program.
- Employee Assistance Program.
- Employee Recognition Programs.
