Process Engineering Manager

Foundry work is tough. It takes grit, it takes hard work, and it takes people

who can think on their feet and solve complex problems.

Are you up to the task?

Our history dates back to 1905, when we began to produce castings in Elyria, Ohio, for the machine tool, gas engine and other industries. Our Hodge Foundry location began operation in 1876 and built a reputation for quality casting from its Greenville, Pennsylvania location. The two foundries joined to form a single company in 2008, which is today known as Elyria Foundry. We are a fast-paced, technically advanced, customer-focused operation creating high-quality, American-made products and we’re looking for individuals who are eager to learn and contribute to the Team!

Position: Process Engineering Manager

Summary:

Plans, coordinates, and directs activities concerned with developing, maintaining, and optimizing foundry manufacturing processes. Maintains and develops standard operating procedures for all molding and core making manufacturing methods. Effectively problem solves and supports activities to drive continuous improvement.

Essential Job Duties and Responsibilities:

• Develops, implements, and coordinates process control programs to prevent or eliminate defects in new or existing products by performing the following duties personally or through subordinate supervisors/staff:
  • Analyzes, evaluates, and presents information concerning factors such as business situations, production capabilities, manufacturing problems, economic trends, and design and development of new products for consideration by other members of management team.
  • Suggests and debates alternative methods and procedures to resolve internal and external root cause(s) of scrap
  • Cooperates with other top management personnel in formulating and establishing company policies, operating procedures, and goals.
  • Develops initial and subsequent modifications of process control program to delineate areas of responsibility, personnel requirements, and operational procedures within program.
• Reviews technical problems and procedures of departments and recommends solutions to problems or changes in procedures.
• Leads process engineering team within the organization.
• Keeps management team informed of significant issues or developments identified with current manufacturing methods and actions being taken to support improvement
• Designs and implement process training programs for key personnel in conjunction with managers.
• Investigates customer complaints regarding quality and maintains related database.
• Directs process engineering team engaged in process improvement/optimization activities
• Supports product engineering team in the analysis, inspection, design, test, and/or integration to assure product quality.
• Prepares and maintains control plans and revises/audits floor processes, responds to customers’ quality concerns
• Lead root cause analysis such as 8D and effective resolutions.
• Performs process engineering reviews of design documentation for compliance with stated requirements, including vendor quality manuals and company quality records.
• Applies statistical process control (SPC) and SQC methods for analyzing data to evaluate the current process and process changes.
• Documents data obtained during all process engineering activities, consistent with company policies and procedures.
• Develops new approaches to solve problems identified during manufacturing process audits
• Communicates significant issues or developments identified during process audits and provides recommended process improvements to management.
• Prepares reports to communicate involvement and results of process improvement activities
• Develops and initiates standards and methods for inspection, testing, and evaluation.
• Devises sampling procedures and designs and develops forms and instructions for recording, evaluating, and reporting quality and reliability data.
• Maintains a working knowledge of government and industry quality assurance standards.

Supervisory Responsibilities:

• Manages a staff of process engineers and process engineering technicians. Is responsible for the overall direction, coordination, and evaluation of these subordinates. Carries out supervisory responsibilities in accordance with the organization's policies and applicable laws. Responsibilities include interviewing, hiring, and training employees; planning, assigning, and directing work; appraising performance; rewarding and disciplining employees; addressing complaints and resolving problems.

Reasoning Ability:

• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists. Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.

Education and/or Experience:

• Bachelor’s degree and a minimum of ten years’ related experience. Sand molding foundry experience required OR related experience

Other Skills and Abilities:

• Ability to maintain, document and report objective evaluation of product quality
• Excellent organizational skills required to maintain detailed documentation and filing of quality records
• Intermediate to advanced skills in Microsoft Office
• Ability to mentor and teach at all levels in the organization
• Strong project management experience
• Ability to work off hours as needed
• Excellent written and verbal communication skills
• Ability to conduct root cause analysis and determine effective resolutions
• Ability to present data in effective formats to management, customers, vendors and plant personnel
• Strong problem-solving techniques
• Ability to perform SPC and SQC

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this Job, the employee is regularly required to talk or hear. The employee is frequently required to sit. The employee is occasionally required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms and climb or balance. The employee must occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus.

Work Environment:

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this Job, the employee is occasionally exposed to moving mechanical parts. The noise level in the work environment is usually moderate.

Job Type:

Full Time, salary exempt.

This job description is in no way intended to state or imply that these duties, responsibilities, qualifications, skills, abilities, work environment, and physical demands (hereinafter referred to as “duties”) are the only duties to be performed and some duties may be reassigned, and other duties may be assigned as required at the sole discretion of Elyria Foundry|Hodge Foundry.

Elyria Foundry|Hodge Foundry provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

Foundry work is tough. It takes grit, it takes hard work, and it takes people who can think on their feet and solve complex problems. Are you up to the task? Our history dates back to 1905, when we began to produce castings in Elyria, Ohio, for the machine tool, gas engine and other industries. Our Hodge Foundry location began operation in 1876 and built a reputation for quality casting from its Greenville, Pennsylvania location. The two foundries joined to form a single company in 2008, which is today known as Elyria Foundry. We are a fast-paced, technically advanced, customer-focused operation creating high-quality, American-made products and we’re looking for individuals who are eager to learn and contribute to the Team! Position: Process Engineering Manager Summary: Plans, coordinates, and directs activities concerned with developing, maintaining, and optimizing foundry manufacturing processes. Maintains and develops standard operating procedures for all molding and core making manufacturing methods. Effectively problem solves and supports activities to drive continuous improvement.

Essential Job Duties and Responsibilities:

• Develops, implements, and coordinates process control programs to prevent or eliminate defects in new or existing products by performing the following duties personally or through subordinate supervisors/staff:
  • Analyzes, evaluates, and presents information concerning factors such as business situations, production capabilities, manufacturing problems, economic trends, and design and development of new products for consideration by other members of management team.
  • Suggests and debates alternative methods and procedures to resolve internal and external root cause(s) of scrap
  • Cooperates with other top management personnel in formulating and establishing company policies, operating procedures, and goals.
  • Develops initial and subsequent modifications of process control program to delineate areas of responsibility, personnel requirements, and operational procedures within program.
• Reviews technical problems and procedures of departments and recommends solutions to problems or changes in procedures.

• Leads process engineering team within the organization.
• Keeps management team informed of significant issues or developments identified with current manufacturing methods and actions being taken to support improvement
• Designs and implement process training programs for key personnel in conjunction with managers.
• Investigates customer complaints regarding quality and maintains related database.

• Directs process engineering team engaged in process improvement/optimization activities

• Supports product engineering team in the analysis, inspection, design, test, and/or integration to assure product quality.
• Prepares and maintains control plans and revises/audits floor processes, responds to customers’ quality concerns
• Lead root cause analysis such as 8D and effective resolutions.
• Performs process engineering reviews of design documentation for compliance with stated requirements, including vendor quality manuals and company quality records.
• Applies statistical process control (SPC) and SQC methods for analyzing data to evaluate the current process and process changes.
• Documents data obtained during all process engineering activities, consistent with company policies and procedures.
• Develops new approaches to solve problems identified during manufacturing process audits
• Communicates significant issues or developments identified during process audits and provides recommended process improvements to management.
• Prepares reports to communicate involvement and results of process improvement activities

• Develops and initiates standards and methods for inspection, testing, and evaluation.
• Devises sampling procedures and designs and develops forms and instructions for recording, evaluating, and reporting quality and reliability data.
• Maintains a working knowledge of government and industry quality assurance standards.

Supervisory Responsibilities:

• Manages a staff of process engineers and process engineering technicians. Is responsible for the overall direction, coordination, and evaluation of these subordinates. Carries out supervisory responsibilities in accordance with the organization's policies and applicable laws. Responsibilities include interviewing, hiring, and training employees; planning, assigning, and directing work; appraising performance; rewarding and disciplining employees; addressing complaints and resolving problems.

Reasoning Ability:

• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists. Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.

Education and/or Experience:

• Bachelor’s degree and a minimum of ten years’ related experience. Sand molding foundry experience required OR related experience

Other Skills and Abilities:

• Ability to maintain, document and report objective evaluation of product quality
• Excellent organizational skills required to maintain detailed documentation and filing of quality records
• Intermediate to advanced skills in Microsoft Office
• Ability to mentor and teach at all levels in the organization
• Strong project management experience
• Ability to work off hours as needed
• Excellent written and verbal communication skills
• Ability to conduct root cause analysis and determine effective resolutions
• Ability to present data in effective formats to management, customers, vendors and plant personnel
• Strong problem-solving techniques
• Ability to perform SPC and SQC

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this Job, the employee is regularly required to talk or hear. The employee is frequently required to sit. The employee is occasionally required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms and climb or balance. The employee must occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus.

Work Environment:

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this Job, the employee is occasionally exposed to moving mechanical parts. The noise level in the work environment is usually moderate.

Job Type:

Full Time, salary exempt.

This job description is in no way intended to state or imply that these duties, responsibilities, qualifications, skills, abilities, work environment, and physical demands (hereinafter referred to as “duties”) are the only duties to be performed and some duties may be reassigned, and other duties may be assigned as required at the sole discretion of Elyria Foundry|Hodge Foundry.

Elyria Foundry|Hodge Foundry provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.