Process Quality Engineer

Responsibilities

• Support and improve Foundry processes including raw material charging, melting, metal treatment, chemistry control, DC casting, homogenization, and related material handling processes.
• Monitor and analyze key process parameters, process capability, scrap, yield, downtime, and quality performance to identify improvement opportunities.
• Lead or support scrap reduction, yield improvement, cost reduction, and process optimization projects.
• Establish, document, and maintain process standards, operating parameters, recipes, SOPs, work instructions, and process controls.
• Perform process trials, data analysis, and structured problem solving to improve process stability and product quality.
• Lead and participate in root cause analysis and corrective actions for process and product nonconformities.
• Develop and maintain Process FMEAs and Control Plans and ensure controls reflect actual process risks and operating conditions.
• Identify process risks and implement appropriate prevention, detection, and error-proofing controls.
• Support SPC, process capability analysis, Measurement System Analysis, and other statistical quality tools as applicable.
• Organize and conduct process, layered, and Quality System audits and follow corrective actions through completion.
• Support internal and external Quality System audits and ensure Foundry processes comply with applicable QMS requirements.
• Lead and support Kaizen and Continuous Improvement activities using Lean/Six Sigma and structured problem-solving methodologies.
• Analyze workflow and value streams to identify waste, process variation, bottlenecks, and opportunities for improved efficiency.
• Establish and monitor Foundry KPIs related to scrap, yield, quality, process compliance, and continuous improvement.
• Partner with Operations and Maintenance to troubleshoot equipment and process-related issues affecting product quality or process stability.
• Review process changes, equipment modifications, and new process implementations to ensure quality and process risks are appropriately addressed.
• Provide technical training and guidance to production personnel on process standards, quality controls, and standardized work.
• Ensure process changes and improvements are properly documented, communicated, implemented, and sustained.
• Promote continuous improvement and a data-driven approach to process and quality performance.
• Perform other process engineering, quality, and continuous improvement activities as required.

Education

Bachelor’s degree in Engineering, Materials Science, Metallurgy, Manufacturing Engineering, Mechanical Engineering, or related technical field.

Skills

• Critical Thinking — Using logic and reasoning to both develop solutions and identify the strengths and weaknesses of alternative solutions, conclusions or approaches to problems.
• Monitoring / Documentation— Monitoring/Assessing current production procedures and standards to identify inefficiencies. Maintaining all production documentation, including owner manuals and relevant documentation for machinery. This responsibility includes updating all documentation when processes change
• Teamwork – Job requires the ability to function as part of a small team, as well as the ability to work independently.
• Integrity — Job requires being honest and ethical.
• Time Management — Managing one's own time and the time of others.
• Dependability — Job requires being reliable, responsible, and dependable, and fulfilling obligations.
• Production and Processing — Knowledge of raw materials, production processes, quality control, industry standards, costs, and other techniques for maximizing the effective manufacture and distribution of goods.
• Good verbal and written communication skills to technical and non-technical audiences of various levels in the organization, e.g., executive, management, individual contributors
• Excellent analytical, decision-making, problem-solving, resourceful and proactive in gathering information and sharing ideas

Qualifications

• Bachelor’s degree in Engineering, Materials Science, Metallurgy, Manufacturing Engineering, Mechanical Engineering, or related technical field.
• 2+ years of experience in manufacturing, process engineering, quality engineering, or continuous improvement preferred.
• Experience in aluminum, metals, casting, foundry, or other heavy manufacturing environments preferred.
• Working knowledge of PFMEA, Control Plans, root cause analysis, corrective action, SPC, and process capability.
• Working knowledge of Lean Manufacturing and Six Sigma tools.
• Experience developing or maintaining SOPs, work instructions, and process documentation.
• Experience with process and/or Quality System auditing preferred.
• Strong analytical and data-driven problem-solving skills.
• Ability to work effectively on the manufacturing floor and collaborate with Operations, Quality, Maintenance, and Engineering.
• Strong written and verbal communication skills.

Working Conditions

This position works in a manufacturing environment. This position operates in shop floor and office environment. Involves: long periods of shop floor activities, frequent stooping, and bending. This position routinely uses standard office equipment.

Pay