Foundry Process Improvement Specialist
Work to drive down foundry operational costs. Optimize sand and metal chemistries to achieve efficiencies in yield, productivity, and equipment longevity. Consider the effects on the entire process when implementing improvements. Serve as sands and metals lab technical expert and analyst. Evaluate options for cost improvement with incoming materials and suppliers. Collaborate with plant supervisors, Engineering, and Quality. This position is heavily involved in production.
A. Essential Functions
1. Find opportunities to reduce costs of the casting process from melt to finishing
2. Perform real time analysis of ductile iron composition and make in process changes to optimize cost per batch.
3. Balance variances with incoming materials to ensure iron quality is maintained and costs are optimized.
4. Provide visibility on the foundries cost performance through metrics and performance indicators
5. Collect, prepare, and analyze ductile iron samples looking for trends and opportunities for improvement.
6. Implement better methods and equipment for controlling iron quality. This may include working with suppliers and/or conducting external research.
7. Troubleshoot melt and sand processing issues.
8. Develop and execute design or change verification plans to confirm expectations are achieved and processes become self-sustaining.
B. Additional Job Responsibilities
1. Work with maintenance to identify and address issues with equipment used in metal or sand production.
2. Perform root cause analysis and coordinate resolution actions for products, processes, and materials.
3. Perform quality department support such as material inspections, process analysis, and/or data gathering.
4. Perform audits of foundry operations with a focus on casting operations.
5. Provide training to lab and production personnel.
6. Obtain buy in for affected activities when making changes and resolving issues.
7. Develop process and procedural documentation for new processes.
C. Minimum Qualifications
1. Bachelor’s Degree or an equivalent combination of education, training, and experience – preferably in Engineering, metallurgy, chemistry, or other technical discipline.
2. Ability to read technical/engineering documents, define technical issues, and conduct statistical analysis.
3. Ability to use tools and equipment, to prepare samples, run lab tests and confirm cast parts meet dimensional and metallurgical specification.
4. Ability to perform visual inspections
5. Effective reading, writing, and general mathematical skills
6. Strong written and oral communication skills
D. Additional Preferred Qualifications
1. Experience in a foundry environment and typical melting practices for Ductile Iron.
2. Working knowledge of metallurgy, chemistry, materials sciences, or related studies or work experience.
3. Working knowledge of Quality Assurance practices such as Lean, 5S, SPC, ISO 9001.Experience with foundry finishing processes and defect recognition
Disclaimer: The above information on this description has been designed to indicate the general nature and level of work performance by employees within this classification. It is not designed to contain or be interpreted as comprehensive inventory of all duties, responsibilities, and qualifications required of employees assigned to this job. Moreover, nothing in this job description restricts the management’s right to assign or reassign duties and responsibilities to this job at any time. Romac believes that each employee makes a significant contribution to our success. That contribution should not be limited by the assigned responsibilities. It is our expectation that each employee will offer their services wherever and whenever necessary to ensure the success of the company.