Die Cast Process Engineer (FLM)

About the role

The Die Cast Process Engineer is responsible for developing, optimizing, and maintaining metal casting processes to ensure safe, efficient, and high-quality production. This role provides technical leadership for foundry operations, supports new product launches, drives process improvements, and works closely with production, quality, maintenance, and tooling teams to achieve operational excellence.

Responsibilities

• Support and improve metal casting processes.
• Develop, document, and maintain casting process parameters, work instructions, and standard operating procedures.
• Troubleshoot production issues related to casting defects and process variability.
• Provide day-to-day engineering support for foundry operations.
• Analyze process capability and implement improvements to reduce scrap and improve quality.
• Collaborate with tooling, maintenance, quality, and production personnel to resolve process and equipment issues.
• Investigate quality concerns and perform root cause analysis.
• Implement corrective and preventive actions to reduce scrap and rework.
• Support new product introductions and production launches.
• Review part designs for manufacturability related to die casting processes.
• Participate in process validation and first article inspections.
• Ensure compliance with safety, environmental, and quality standards.

Requirements

• Bachelor's Degree in Mechanical Engineering, Metallurgical Engineering, Manufacturing Engineering, or related discipline.
• Minimum two (2) years of experience in die casting or metal casting manufacturing; five (5) years preferred.
• Knowledge of metal casting processes, metallurgy, and solidification principles.
• Experience in a production or foundry environment preferred.
• Ability to read and interpret engineering drawings and GD&T.
• Strong problem-solving and analytical skills.
• Hands-on, production-focused mindset.
• Effective communication and cross-functional collaboration skills.

Position Requirements

• Utilize Lean Manufacturing, Six Sigma, and continuous improvement methodologies.
• Assist with FMEA, SPC, and control plan development.
• Support die tooling reviews and process optimization.
• Support ergonomic, safety, and risk-reduction initiatives.
• Successfully communicate and collaborate with engineering, production, maintenance, quality, customers, and suppliers.

Work Environment

• Collaborative, fast-paced manufacturing environment.
• Manufacturing and foundry environments with exposure to heat, noise, and industrial equipment.
• Travel to customer or supplier sites as needed.
• May require on-floor support during production trials, launches, and issue resolution.
• Ability to lift up to 30 pounds and perform essential job functions with or without reasonable accommodation.