Senior Process Metallurgist

Charter Casting is hiring a Senior Process Metallurgist!

Alternative Job Titles: Senior Manufacturing Metallurgist, Lead Process Metallurgist, Senior Metallurgical Engineer

Job Summary:

As a Senior Process Metallurgist, you will provide technical leadership with a strong focus on metallurgical and process engineering across the Melt, Laboratory, and Continuous Casting operations. You will apply materials science, metallurgy, and manufacturing-process expertise to improve safety, quality, productivity, and cost.

Partnering closely with Operations and cross-functional teams, you will troubleshoot complex technical issues, strengthen process controls and standards, optimize melting and casting practices, support new-product development, and implement sustainable process improvements. This role serves as a primary technical resource for manufacturing process performance and product quality.

Position specifics:

• Location: Woodstock, IL

• Schedule: Onsite

• Travel: Up to 10% travel

• Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor employment visas at this time.

Key responsibilities:

Metallurgical & Process Engineering Leadership

• Provide technical leadership for Melt, Laboratory, and Continuous Casting processes by developing and improving metallurgical standards, manufacturing processes, and operating practices.

• Develop and improve melt recipes, process instructions, and standards for molten metal processing, product analysis, and product release.

• Evaluate and adjust manufacturing processes based on raw material quality, chemical composition, cost, product requirements, and process performance.

• Improve melting and continuous casting processes, including die and cooler design, crucible design, refractory practices, molten metal handling, and critical process variables.

• Strengthen metallurgical quality and process consistency for gray and ductile cast iron products.

Process Optimization & Technical Problem Solving

• Partner with Operations to troubleshoot manufacturing, process, and quality issues; lead root cause analysis and implement sustainable corrective actions.

• Analyze manufacturing, laboratory, quality, and process data to identify trends, reduce manufacturing losses, improve yield, and strengthen process capability.

• Lead process improvement projects through data analysis, process validation, production trials, and implementation of sustainable improvements.

• Investigate and resolve quality problems identified during manufacturing or through customer returns, including defect and failure analysis.

• Apply process engineering and continuous-improvement tools, including Design of Experiments, statistical analysis, process mapping, DMAIC, root cause analysis, and Lean principles.

Technical Systems, Projects & Product Support

• Maintain MES process master data and provide technical support for manufacturing system enhancements, troubleshooting, and process optimization.

• Support capital projects involving manufacturing equipment, tooling, furnaces, holders, refractory systems, and process improvements.

• Serve as the primary technical resource for new-product quoting by evaluating manufacturing feasibility, process capability, and technical risk.

• Partner with Procurement in qualifying new suppliers and ensuring incoming raw materials meet required technical and quality standards.

• Support the development and qualification of new or improved products, materials, manufacturing technologies, and process capabilities.

Cross-Functional Collaboration & Technical Expertise

• Collaborate with Operations, Quality, Maintenance, Engineering, Supply Chain, Sales, and Technical Services to solve technical problems and support strategic initiatives.

• Support Commercial and Sales teams as a technical resource for customer application questions, quality concerns, processing recommendations, and product performance.

• Develop and maintain manufacturing standards, work instructions, operating procedures, and technical documentation.

• Share technical knowledge and mentor employees on metallurgy, materials science, process controls, manufacturing processes, and continuous-improvement practices.

• Support Environmental, Quality, and Safety Management Systems and ensure compliance with company policies and regulatory requirements.

What you’ll need:

• Bachelor’s Degree in Metallurgical Engineering, Materials Science, or a related engineering discipline.

• Five or more years of experience in a metallurgical, materials, manufacturing, or process engineering environment.

• Strong understanding of metallurgy, materials science, cast iron manufacturing, process control, and data analysis.

• Demonstrated success solving complex technical problems and improving manufacturing processes.

• Strong analytical, troubleshooting, root cause analysis, and problem-solving skills.

• Ability to lead cross-functional projects and influence others without direct authority.

• Strong verbal, written, and presentation skills.

• Experience with SolidWorks 2D/3D CAD software, or willingness to learn, to support tooling, equipment, and process improvements.

• Proficiency with Microsoft Office and manufacturing data analysis tools.

• Ability to manage multiple priorities in a fast-paced manufacturing environment.

• Demonstrated commitment to safety, quality, and continuous improvement.

• Willingness to travel up to 10%.

Nice to haves:

• Master’s Degree in Metallurgical Engineering, Materials Science, Engineering, Operations Management, or a related field.

• Experience with induction melting and production of gray and ductile cast iron.

• Experience with continuous casting operations and cast iron manufacturing.

• Experience with metallurgical laboratory equipment, including optical emission spectrometers and LECO analyzers.

• Experience in defect analysis, failure analysis, and customer-facing technical support.

• Experience developing new or improved products.

• Experience with ISO or Quality Management Systems.

• Experience with MES and ERP systems supporting manufacturing processes; Oracle ERP experience is a plus.

• Lean Manufacturing and/or Six Sigma Green Belt certification, or equivalent continuous-improvement experience.

• Experience leading or supporting capital improvement projects involving manufacturing equipment, tooling, furnaces, holders, or process improvements.

• Proficiency with statistical analysis, process mapping, and data visualization tools.

Take the next step in your career, apply today!

About Charter Casting

Charter Casting is a premier U.S. partner and casting supplier for precision-engineered iron solutions. We deliver large, complex iron castings and DuraBar®, the industry’s leading continuous cast iron bar, with the consistency and performance customers depend on.

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