Casting Specialist

Position Summary

The Casting Specialist provides technical support for foundry operations to improve safety, quality, and productivity by developing robust casting processes, troubleshooting defects, and implementing controlled documentation and continuous improvement initiatives.

Essential Functions

• Support and improve foundry processes including molding, melting, pouring, shakeout, cleaning, and finishing activities as applicable.
• Analyze casting defects and lead root cause investigations; implement corrective and preventive actions.
• Develop and maintain process documentation, including work instructions, process parameters, and control plans under change control.
• Partner with the Quality team on inspection strategies, defect detection, and containment activities.
• Support process trials and validation activities; document results and standardize successful process improvements.
• Collaborate with Patternmaking, Engineering, and Production on tooling, pattern improvements, and process capability.
• Identify and execute continuous improvement projects to reduce scrap, rework, and cycle time.
• Support safety and environmental compliance by integrating hazard controls into process design and standard work.
• Provide technical support to supervisors and operators; train production teams on process changes and best practices.
• Track foundry KPIs and report trends and improvement progress to leadership.

Additional Skills by Level

Level I

• Supports documentation and basic troubleshooting with guidance.
• Learns foundry standards, casting processes, and common defect modes.

Level II

• Independently leads defect elimination and process optimization projects.
• Improves process stability, consistency, and capability.

Level III

• Leads advanced casting process development and modernization initiatives.
• Establishes site-wide foundry process standards and mentors junior team members.

Job Requirements and Qualifications

Education, Experience, or Formal Training

• Bachelor's degree in Engineering (Metallurgical, Materials, Mechanical, Manufacturing) or equivalent industry experience.
• Three (3) or more years of foundry or casting process experience preferred.
• Strong analytical and problem-solving skills.
• Ability to work effectively in an industrial manufacturing environment.

Working Environment

Work is performed in a foundry environment with exposure to heat, dust, noise, molten metal, and industrial hazards. Personal Protective Equipment (PPE) is required. Extended hours may occasionally be necessary to support process trials, production demands, or urgent defect containment activities.

Physical Demands

• Frequent walking and standing throughout the workday.
• Ability to wear required PPE, including heat-resistant protective equipment.
• Occasional lifting of up to 30 pounds (samples, tools, and materials).
• Ability to safely work around high-temperature manufacturing processes.

Key Performance Indicators (KPIs)

• Foundry scrap rate (by defect category)
• Foundry-related rework rate
• First Pass Yield (FPY)
• Defect recurrence rate after corrective actions
• Corrective action closure time and effectiveness
• Cycle time and throughput for key foundry operations
• Process adherence audit pass rate
• Safety incidents and near-misses in foundry operations
• Control plan coverage for critical foundry processes
• Training completion for process changes

SMART Goals

• Reduce foundry scrap by 12% within 9 months by eliminating the top three defect drivers using structured Root Cause Analysis (RCA).
• Reduce foundry rework by 10% within two quarters through improved process controls and operator training.
• Increase Foundry First Pass Yield by 6 percentage points within two quarters through standardized work and improved process controls.
• Reduce defect recurrence by 25% within six months by verifying corrective action effectiveness and updating documentation.
• Close 90% of foundry corrective actions within 30 days for two consecutive quarters through improved escalation and accountability.
• Improve throughput on one foundry bottleneck operation by 8% within six months through workflow and setup improvements.
• Achieve 95% or greater process adherence during monthly audits within 120 days through standardized work and employee training.
• Increase near-miss reporting by 25% within six months and close all resulting action items within 14 days .
• Implement documented control plans for 100% of critical foundry processes within 120 days .
• Achieve 100% training completion for all critical foundry process changes within 10 business days for three consecutive months.