Foundry Engineering Manager

Company Overview

Castalloy is a division of Norican Group. Castalloy is one of the leading producers of high alloy castings and has been producing engineered cast components for over 30 years. The molding processes include airset and shell that enable us to produce castings which have excellent dimensional accuracy and superior surface finish.

Castalloy’s diverse customer base and ability to serve our customers’ needs have earned us a dominant position in the high alloy casting and fabrication industry. We offer contract manufacturing to customer design, custom designs for specific applications and a wide range of standard products.

Continued modernization and automation of manufacturing equipment and environmental controls enable us to maintain our leading position in the marketplace.

Job Title: Engineering Manager

Location: Waukesha, WI

Reports To: Managing Director

Part I - Position Purpose

This position plays a pivotal role in optimizing our engineering and production processes. Alongside the support of the engineering team, this position is responsible for managing the design, development and enhancement of manufacturing processes, and any improvements that will ensure efficiency, profitability and quality of output. This person’s expertise will be a spearhead in driving our organization’s innovation with technological advancements in the industry in all applicable ways. There is extensive departmental collaboration with internal customers in integrating the highest standard of engineering solutions and meeting external customer expectations. This is a heavy emphasis of a hands-on approach to problem solving, and undeniable commitment to fostering a culture of continuous improvement, servant leadership and safety for our organization and all other stakeholders.

Part II - Job Functions

• Identify opportunities or implement changes to improve products or reduce costs using knowledge of fabrication processes, tooling and production equipment, assembly methods, quality control standards, or product design, materials and parts.
• Determine root causes of failures using statistical methods and recommend changes in designs, tolerances, or processing methods.
• Provide accurate technical expertise and support related to relevant manufacturing happenings.
• Incorporate innovative and technologically relevant new methods and processes to improve existing operations.
• Manage quality and engineering personnel with respect and servant leadership approach.
• Troubleshoot new or existing product problems involving designs, materials, or processes with all applicable parties.
• Thoroughly review product designs for manufacturability or completeness and provide optimized solutions.
• Train production management and personnel in new or existing methods and provide an explanation for why the change is needed.
• Prepare necessary technical documentation for new manufacturing processes or engineering procedures within ISO compliance.
• Apply continuous improvement methods such as lean manufacturing to enhance manufacturing quality, reliability, or cost-effectiveness.
• Investigate or resolve operational and quality problems, such as material use variances, reoccurring quality defects and oversight of scrap trends with critical analysis of scrap contributions.
• Estimate costs, production times, or staffing requirements for current and new designs, in addition to regular audit of current designs to ensure updated costing factors.
• Periodically evaluate manufactured/finished products to ensure all customer specifications and quality standards are met.
• Purchase all necessary equipment, materials, or parts as needed to ensure the engineering department has full capability to successfully do their jobs.
• Design and implement testing methods and test finished products or process capabilities to establish standards or validate process requirements.
• Ability to effectively complete casting defect analysis and make corrections wherever necessary.
• Regularly prepare reports summarizing information or trends related to manufacturing performance.
• Is up to date with current and significant events related to market and industry changes, willingness to participate in educational programs, conferences and workshops, and/or participation in professional organizations to keep abreast of developments in the manufacturing field.
• Apply all practical lean concepts in alignment with operations team.
• Ability to complete time studies and effectively train engineering direct reports using adult learning strategies.
• Ability to complete a pattern layout and apply the highest quality standard gating concepts.
• Ability to spend up to 8 hours on the production floor standing.

Part III - Qualifications and Experience

• Bachelor’s degree in business or engineering or metallurgical science preferred.
• 5-10 years of experience related in foundry preferred; prior experience working with steel, white iron, and/or white ductile iron desired.
• At least 5 years of management experience.
• Experience with tooling and gating in a foundry context.
• Extensive experience with CAD, SolidWorks and other relevant engineering software.
• Experience with solidification modelling.
• At least proficient in Microsoft Office.
• Occasional local travel up to 10%
• Ability to work in office and manufacturing setting, as there is significant presence required on shop floor to meet oversight of engineering and manufacturing standards and procedures.

Part IV - Personal Characteristics

• Shows ability to comprehend a wide scope of complex technical topics, abstract ideas and specialized information.
• Ability to use critical thinking and reasoning to solve a variety of simple and complex problems.
• Attention to the minute details of a project or task with ability to prioritize where focus is needed.
• Accepts responsibility and takes account for their actions in all applicable scenarios.
• Initiative to look beyond the standard solutions, with open-mindedness for feedback and input from other perspectives.
• Exemplary self-management and ability to organize oneself to effectively supervise and lead by example for others.
• Ability to effectively build and maintain relationships with fellow team members and all other relevant stakeholders.
• Highest possible ethical and professional standards.
• Behaves in accordance with expressed beliefs and commitments.
• Able to work well under pressure and maintain composure in emergency and stressful situations.
• Influential and motivational leadership skills to bring a team together toward a common goal.
• Outstanding written and verbal communication skills to meet the needs of varying communication styles.