Foundry Engineer
Job Description
Position Summary:
Provides foundry process engineering support to improve safety, quality, and productivity
by developing robust casting processes, troubleshooting defects, and implementing controlled documentation and improvement actions.
Essential Functions:
• Support and improve foundry processes including molding, melting, pouring, and finishing activities as applicable.
• Analyze casting defects and lead root cause investigations; implement corrective and preventive actions.
• Develop and maintain process documentation (work instructions, parameters, control plans) under change control.
• Partner with Quality on inspection strategy, defect detection, and containment activities.
• Support process trials and validation; document results and standardize successful changes.
• Collaborate with Patternmaking and Production on tooling/pattern improvements and process capability.
• Identify and execute continuous improvement projects to reduce scrap, rework, and cycle time.
• Support safety and environmental compliance by integrating hazard controls into process design and standard work.
• Provide technical support to supervisors and operators; train teams on process changes and best practices.
• Track foundry KPIs and report trends and improvement progress to leadership. Additional Skills by Level
Level I: Supports documentation and basic troubleshooting with guidance; learns foundry standards and defect modes.
Level II: Independently leads defect elimination and process optimization projects; improves stability and capability.
Level III: Leads advanced foundry process development and modernization initiatives; sets site-wide standards.
Job Requirements and Qualifications
Education, Experience, or Formal Training:
• Bachelor’s degree in Engineering (Metallurgical/Materials/Mechanical/Manufacturing) or equivalent experience.
• 3+ years foundry or casting process experience preferred.
• Strong analytical/problem-solving skills and comfort working in industrial environments.
Working Environment:
Foundry environment with heat, dust, noise, and industrial hazards; PPE required; may require extended hours for trials or urgent defect containment.
Physical Demands:
• Frequent walking/standing; ability to wear PPE including heat-resistant gear as required.
• Occasional lifting up to 30 lbs (samples, tools) and ability to work near hightemperature processes safely.
KPIs:
• Scrap rate in foundry (by defect category)
• Rework rate (foundry-related)
• First Pass Yield (foundry processes)
• Defect recurrence rate after corrective actions
• Corrective action closure time and effectiveness
• Cycle time/throughput for key foundry operations
• Process adherence audit pass rate
• Safety incidents/near-misses in foundry areas
• Control plan coverage for critical foundry processes
• Training completion for process changes
SMART Goals:
• Reduce foundry scrap by 12% within 9 months by eliminating top-3 defect drivers using structured RCA.
• Reduce rework by 10% within 2 quarters through improved process controls and operator training.
• Increase foundry FPY by 6 percentage points within 2 quarters via standard work and control points.
• Reduce defect recurrence by 25% within 6 months by verifying corrective action effectiveness and updating documentation.
• Close 90% of foundry corrective actions within 30 days for 2 consecutive quarters through escalation routines.
• Improve throughput on one foundry constraint operation by 8% within 6 months through workflow and setup improvements.
• Achieve ≥95% process adherence in monthly audits within 120 days by reinforcing standard work and training.
• Increase near-miss reporting by 25% within 6 months and close actions within 14 days.
• Implement control plans for 100% of identified critical foundry processes within 120 days.
• Achieve 100% training completion for critical foundry process changes within 10 business days for 3 consecutive months.
